flow control january 2015
TRANSCRIPT
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 145
JANUARY 2015 Vol XXI No 1wwwFlowControlNetworkcom
SOLUTIONS for FLUID MOVEMENTMEASUREMENT amp CONTAINMENT
special section | pg 23
PUMPS BEARINGSAND SEALS
TECHNOLOGY REPORT
API 624 Valve EmissionsSTANDARD Update
Considering K-FACTOR ADJUSTMENTS
How to CALCULATE
Orifice-Plate FLOW RATE
1 9 9 5 - 2 0 1
51 9 9 5 - 2 0
1 5
20th20th
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 245
Twitterfollow Flow Control on Twitter
Google+connect with Flow Control on Google+
E-Newsget e-mail updates from Flow Control
Advertisefind out how Flow Control can help market
your products amp services
Connect
LinkedIn join Flow Controlrsquos LinkedIn group
Facebookbecome a Flow Control Facebook fan
FlowTubeFlow Controlrsquos fluid handling video archive
Subscribereceive the print or digital edition
of Flow Control
reg
SOLUTIONS FOR FLUID MOVEMENT MEASUREMENT amp CONTAINMENT
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 345
The only press fittings in multiple materials
The g lobal leader
in plumbing heat ingand p ipe jo in ing systems
Industrial press fitting solutionsfor clean controlled installations
Do more with Viega press fitting solutions
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bull Only Viega offers the patented
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bull More than 1400 tting choices
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bull Viega ProPressreg and Viega MegaPressreg
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bull Viega MegaPress the only carbon steel
press solution for water and gas
bull No ame is required to install Viega
products eliminating noxious fumes
hot work permits and fire watches
wwwviegaus | 1-800-976-9819
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 445
Do you need flow measurement with online density compensation
Available now with OPTISWIRL 4200 from KROHNE
Featuring integrated pressure and temperature sensors the new OPTISWIRL 4200
vortex flowmeter provides online density compensation for all types of gas and steam
The OPTISWIRL 4200 even masters fluctuating operating conditions with effortless
precision and helps to significantly reduce installation costs Itrsquos the smart choice for
auxiliary and supply processes in a broad range of applications
Developed for use in continuous volume flow measurements in safety-related
applications the OPTISWIRL 4200 is in full compliance with the IEC 61508 SIL2 safety
standard Units can be easily switched from non-SIL mode to SIL mode without the need
to call out a service technician
Minimising downtime is critical for your business Thatrsquos why the OPTISWIRL 4200
provides redundant data storage of all calibration and configuration data in the display
memory and the electronics module ndash transferring data to replacement modules is a snap
When efficiency and flexibility matter most the OPTISWIRL 4200 is the definitive choice
KROHNE ndash Flow measurement is our world
Please see our website for more information
The All-in-OneSolution
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 545
featurescontents
16 The Two-Wire Advantage
By Steve Milford Advances in two-wire instrumentation specifically in relation to flow-
meters have enabled significant cost benefits for new technology in-
stallations in terms of capital investment and cost of ownership
20 Compensating for CompressibilityIn Gas Flow MeasurementBy Kevin Clark
K-factor adjustment is a key factor in ensuring accurate gas flow mea-
surement for inline turbine meters The K-factor is established by an
initial factory calibration In the case of a non-compensated flow moni-
tor any variations in pressure and temperature will require manual
adjustments to the K-factor
2 | January 2015 Flow Control Magazine
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 qualied subscribers Non-qualied subscrip-
tion rates in the US 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 t he Circulation
Manager for more wire transfer information Single copies $10
per issue in the US and Canada Single copies $15 per is-
sue in all other countries All subscription payments are due in
US funds
POSTMASTER Send address changes to Flow Control PO BOX
2174 Skokie IL 60076-7874 Periodical postage rates paid at
Subscription Information Toll Free 8667214807Outside US 8477631867Mail PO Box 2174Skokie IL 60076-7874E-mail flowcontrolhalldatacom
SubscribeRenewChange of Addresswwwflowcontrolnetworkcomsubscribe
Birmingham AL 35242 and additional mailing ofces
copy Entire contents copyright 2015 No portion of this publica-
tion may be reproduced in any form without written permis-
sion of the publisher Views expressed by the bylined con-
tributors should not be construed as reecting the opinion
of this publication Publication of productservice information
should not be deemed as a recommendation by the publisher
Editorial contributions are accepted from the uid handling
industry Contact the editor for details Productservice infor-
mation 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
1 616
Pumps Bearings amp Seals Technology Report SPECIAL SECTION PAGE 23
24 The Complicated Case of Compressors
with Side-StreamsBy Amin Almasi
28 How Pumping Systems Design AffectsSealing PerformanceBy Chris Boss
32
Bearings amp Couplings Suppliers Position
to Drive Market GrowthBy Amy W Richardson
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 645
Do you know whatrsquos
gone out the window
at your facility
Magnetrolreg energy management solutions monitor and measure the energyflowing through your facility to reduce utility costs and make processes moreefficient Easy to install and operate TA2 thermal flow meters provide you withan efficient environmentally responsible way to manage compressed air andnatural gas cost centers
Make MAGNETROL Thermatel reg TA2 mass flowmeters part of your energy management strategyVisit magnetrolcomthermalmassflow or contact
your MAGNETROL representative for more information
Measure and control your compressed
air and natural gas energy costs with
Thermatelreg TA2
991266 PDJQHWUROFRP Write in 3 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
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1 9 9 5 - 2 0 1
51 9 9 5 - 2 0 1
5
20th20th january 2015 | Vol XXI No 1
4 | January 2015
Flow Control Magazine
departmentscolumns6 EDITORrsquoS FILE
4 flow things you need to know aboutthis month
14 APPLICATIONS CORNERa coriolis mass flowmeter providesa better solution
39 WORD SEARCH temperature measurement
40 QUIZ CORNER how to calculate orifice plate flow rate
Cover imagesFlowmetercourtesyEndress+HauserBackgroundiStock
8 NEWS amp NOTES api 624 valveemissions update intelligent features toboost desal pumps market hydraulic fractur-ing water treatment on the rise
34 UP CLOSE with Micro Motionrsquos Model5700 Coriolis Transmitter
35 NEW PRODUCTS
36 WEB RESOURCE FILE
38 ADPRODUCT INDEX
S I N C E 1 9 5 8
Itrsquos More than a Check Valve
Itrsquos a Check-All
When You Need Absolute Precision
CHECK-ALL IS THE ONLY CHOICE
Our spring loaded check valves are assembled
to your exact needs ensuring absolute precision
and reliability They work like they should Plus
most lead times are less than one week Thatrsquos
what makes Check-All the only choice
Get me a Check-AllManufactured in
West Des Moines Iowa USA515-224-2301 bull salescheckallcom bull wwwcheckallcom
Write in 4 or Request Info Ins tantly at wwwFlowControlNetworkcomfreeinfo Write in 5 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
Return on investment calculations for plant upgrade or new
plant construction projects may go through several iterationsbefore the trigger is finally pulled or indeed not pulledldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 845
The new Ultratrade 8c The capability and performance
your market demands
Copyright copy FMC Technologies Inc All Rights Reserved
FMC Technologiesrsquo Ultra 8c ultrasonic owmeter shares the advanced technology
of the next generation Smith Meterreg Ultra Series meters With its touchscreen
interface upgradable memory and high-speed processor the Ultra 8c provides
cutting-edge performance and diagnostic ability And with additional measurement
paths the Ultra 8c has even better cross-ow and swirl compensation for improved
accuracy and repeatability Whether for leak detection or custody transfer theUltra 8c gives you the assurance of superior performance in the eld even for the
most viscous crude oils in todayrsquos market
For more information visit wwwfmctechnologiescomultrafc
wwwfmctechnologiescom
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 945
20 Years of Flow Control This
year marks the 20th Anniversary of
Flow Control magazine Launched
in 1995 with the aim of serving technical
professionals involved with designing oper-
ating and maintaining fluid handling systems in a wide range of
industries Flow Control has leveraged its many years of experi-
ence to establish a unique niche and reputation for providinghigh-quality information to you our subscribers I congratulate everybody who helped
Flow Control get to where it stands today Herersquos to another 20 years of success
Training Time Itrsquos a new year and we have two new
training opportunities for
you to enhance your skillset in 2015
Regular Flow Control columnists Da-
vid W Spitzer and Larry Bachus will
be presenting three-day courses on
Flow Measurement and Pumping
Systems respectively I encourage you and your colleagues to take ad-
vantage of these important training
opportunities For more details see
flwctrlcomflowseminar amp
flwctrlcompumpguy
Oil amp Gas Gender Gap Results of a
new global workforce survey conduct-
ed by OilCareerscom and Air Energi
show a gender gap in the oil amp gas industry
persists despite ongoing efforts to recruit more
women into the industry According to hiring
managers the
top three factors
that significantlycontributed to
the gender gap
in the oil amp gas
industry are
1 A lack of women entering the industry (55
percent)
2 An industry culture created by a male-domi-nated environment (53 percent)
3 The logistics requirement ie travel shift
and working patterns in the field (30 percent)
For more on this story and an infographic seeflwctrlcomog_gendergap
Rockwell Automation Fair 2014 Our colleagueKevin Parker at Processing magazine attended the
annual Rockwell Automation Fair Nov 9-10 in
Anaheim Calif Parker gleaned some interesting perspec-
tive on key trends in process automation including
1 Hardware and software are more blended than ever
2 Fog computing (a kind of cloud computing) is making
headway in industrial engineering environments where latency is a critical concern
For Parkerrsquos full report from the Automation Fair see flwctrlcomrockwellfair2014
DITORrsquoS FILE
6 | January 2015
Flow Control Magazine
4 Flow Things You Need to Know
GROUP PUBLISHERPROCESSINGFLOW CONTROL
MICHAEL C CHRISTIAN | (908) 507-5472mikecgrandviewmediacom
NATIONAL ACCOUNTS MANAGERJIM SEMPLE | (908) 963-3008 jsemplegrandviewmediacom
EXECUTIVE DIRECTOR OF CONTENTMATT MIGLIORE | (610) 828-1711
mattgrandviewmediacom
MANAGING EDITOR AMY W RICHARDSON | (205) 408-5050
arichardsongrandviewmediacom
COLUMNISTS
LARRY BACHUSDAVID W SPITZER JESSE YODER
ART DIRECTORJULIE FLYNN
juliegrandviewmediacom
MANAGER - DIGITAL OPERATIONSMARY BETH ROMANO
SUBSCRIPTION amp REPRINT REQUESTSflowcontrolhalldatacom
Administrative TeamGENERAL MANAGER
BARRY LOVETTE
CHIEF OPERATIONS OFFICERBRENT KIZZIRE
VICE PRESIDENT OF FINANCEBRAD YOUNGBLOOD
VICE PRESSIDENT OF B2B GROUPMIKE WASSON
CHIEF REVENUE OFFICERCHRIS DOLAN
VP AUDIENCE DEVELOPMENTDELICIA POOLE
AUDIENCE DEVELOPMENT MANAGER ANNA HICKS
DIGITAL AUDIENCEDEVELOPMENT ANALYST
STACY BARNES
EDITORIAL ADVISORY BOARDLarry Bachus Bachus Company IncGary Cornell Blacoh Fluid Control
Jeff Jennings Equilibar LLCMitch Johnson JMS SoutheastPeter Kucmas Elster Instromet
Jim Lauria Water Technology Executive
John Merrill PE EagleBurgmann IndustriesSteve Milford Endress+Hauser US Tom OrsquoBanion Emerson Process
Management Micro MotionDavid W Spitzer PE Spitzer and Boyes LLC
Tom Tschanz McIlvaine Company John C Tverberg Metals and Materials
Consulting EngineersJesse Yoder PhD Flow Research Inc
WINNER
WINNER WINNER
PERSPECTIVES FROM THE MONTH THAT WAS IN THE WORLD OF FLOW CONTROL
WINNER WINNER
THE
NETWORK
1
2 3
4
1 9 9 5 - 2 0
1 51 9 9 5
- 2 0 1 5
20th20th
Matt Migliore Executive Director of Content MattGrandViewMediacom
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1045
Endress+Hauser Inc
2350 Endress Place
Greenwood IN 46143
infousendresscom
ww wusendresscom
Sales 888-ENDRESS
Service 800-642-8737
Fax 317-535-8498
Guided wave radar level products - built for safety precision and efficiency
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bull Seamless integration into control or asset management systems
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The newest generation of Micropilot
Taking your process to the next level
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1145
HE OUTLOOK | News amp Notes
1 ISO15848 ldquoMeasurement test and qualification proce-
dures for fugitive emissionsrdquo
a Part I ndash ldquoClassification system and qualification proce-dures for type testing of valvesrdquo
b Part II ndash ldquoProduction acceptance test of valvesrdquo
2 API 622 ldquoType Testing of Process Valve Packing for Fugitive
Emissionsrdquo
3 End-user defined fugitive emission reduction requirements
Key aspects of valve testing per API 624 include
The standard covers rising and rising-rotating stem
valves up to 24rdquo diameter
Class 1500 valves are not covered
The test medium is methane
310 test cycles are required with three thermal cycles Temperature application range is from -29 C to 538 C
with last cycle 10 cycles user-defined (can be -45 C)
Re-tightening of gland bolts is not permitted during test
Valve stem test orientation is vertical
Several valves must be tested to achieve API 624 com-
pliance Similar industry principles applied to test valves
qualify two nominal sizes smaller one size larger and one
pressure class below
Allowable leakage is 100 PPM maximum
Gate and globe valves need to be tested separately
For example Gate Valves per API602 four tests API600
eight tests (up to 20rdquo diameter) API 603 eight tests andfor Globe Valves per API 602 four tests
Test valves should be production valves not specially
manufactured test valves
As a result of the release of API 624 testing companies have
been gearing up for an increase in the number and size of
test valves and new test houses are coming to market Withthis in mind implementation of API 624 needs to be carefully
monitored and claims from valve manufacturers should be
validated by requesting to view test results Important factors
to be mindful of include
Number of cycles on some valves could be detrimental
to packing as certain smaller size valves donrsquot come with
grease ports to keep the stem lubricated all of the time
Test failures of valve stem threads yokes and glands
Grease traps into packing and causes leakage
At higher temperatures a few greases create volatile
organic compound and burn off
Testing in vertical generates more heat in yoke area
Certain challenges need a good testing company that has
experience in testing on fugitive emissions and provides
guidelines to manufacturers in terms of use of packing valve
grease testing requirements etc
A preliminary survey was conducted with end-users regard-
ing current utilization and application of API 624 For a sum-
mary of responses from this survey visit flwctrlcom1oWijWz
Gobind Khiani PEng is with Fluor Canada Ltd Khiani has
spent 20-plus years in the energy and power business and 10-
plus years in the Western Canadian oil and gas industry Hecan be reached at 403 850-6982 or gobindkhianifluorcom
Valve Standards UpdateEnd-users ramp up compliance efforts for API 624
as new specifications emerge on the horizon
8 | January 2015
Flow Control Magazine
By Gobind Khiani
In the May 2014 issue of Flow Control (page
16) the new standard API 624 ldquoType Testing
of Rising Stem Valves Equipped with Graphite
Packing for Fugitive Emissions First Editionrdquo was
addressed This standard which was published
and put into effect in February 2014 estab-
lishes guidelines for testing industrial valves for
emissions compliance Since the publication ofthe May article further requests from industry
have spurred the creation of another specifi-
cation API 641 ldquoType Testing of Quarter-Turn
Valvesrdquo and an API ldquoPiping and Valvesrdquo commit-
tee has been formed Regulators and end-users
are also working on
1992 1998 2003 2008 2013 2020
4
35
3
25
2
15
1
05
0
M i l l i o n o f
t o n n e s y e a r Will API 624
have a stepeffect in reducing
fugitiveemissions
Global valve fugitive emissions
End User response at best
End User response actual
S O U R C E G O B I N D K
H I A N I
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1245
Intelligent Features to Boost Global WaterDesalination Pumps Market
The Global Water Desalination
Pumps Market is expected to grow
at a CAGR of 77 percent from 2015 to
2019 according to a new report from
TechNavio (wwwtechnaviocom)
The report shows demand for water
treatment has increased significantly in
developing countries where fresh wa-
ter resources can be scarce Providing
clean and potable water to huge popu-
lations has become a priority which is
pushing the demand for water desalina-tion pumps in the market according to
TechNavio
The report emphasizes the emer-
gence of intelligent pump systems as
a major driver of market growth In-
telligent pumps possess the ability to
regulate flow and pressure and these
systems can automatically adjust to
process and pump system changes
ldquoIntelligent pump systems are be-
ing adopted by many manufacturers
because of the high level of fault toler-
ance ability which leads to a significant
reduction in the total cost of owner-
shiprdquo said Faisal Ghaus vice president
of TechNavio in a news release ldquoThe
adoption of these systems will also
help industries comply with current Eu-
ropean Union regulations in relation toreduction in energy consumptionrdquo
The growing demand for clean wa-
ter worldwide will continue to augment
the demand for water desalination sys-
tems which will propel the Global Water
Desalination Pumps Market during the
forecast period
trendlines
wwwflowcontrolnetworkcom January 2015 | 9
Write in 8 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
Intelligent pump sys-tems are being adopt-
ed by many manufac-
turers because of the
high level of fault tol-
erance ability which
leads to a significant
reduction in the total
cost of ownership
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1345
HE OUTLOOK | News amp Notes
10 | January 2015
Flow Control Magazine
Hydraulic Fracturing WaterTreatment amp Reuse Expected to Soar
Wastewater treatment spending for
hydraulic fracturing is expected to
grow almost three-fold from $138 mil-
lion in 2014 to $357 million in 2020 in
the US according to a new report from
Bluefield Research
The US hydraulic fracturing industry
consumes over 1 billion barrels of wa-
ter annually producing 450ndash500 mil-
lion barrels of contaminated water for
disposal with only about 14 percent
treated and reused Bluefield cites watersupplies increasingly at risk tighter regu-
lations emerging in key states and costs
of disposal on the rise as factors con-
tributing to the substantial rise in water
treatment and reuse which is expected
to account for 27 percent of total pro-
duced and flowback water by 2020
Overall the US hydraulic fracturing
industry will spend $638 billion in 2014
on water management Water transport
and disposal costs will account for 66
percent of the total water managementspent this year with treatment compris-
ing roughly 2 percent
Bluefield reports water scarcity in
Western US states has had little im-
pact to date on fracturing water supply
but that is likely to change if droughts
persist Meanwhile state regulators are
beginning to tighten control of produced
water disposal In Pennsylvania where
policymakers in 2010 placed discharge
limits on wastewater from unconven-
tional oil amp gas operations statewide
treatment and reuse rates for the Mar-
cellus jumped to 90 percent in 2014
The increasing cost of transport and
injecting water into wells mdash now ac-
counting for 66 percent of water servicesspending mdash and the improving cost
structures of treatment provide another
driver of reuse Bluefield reports Well
operators that employ treatment and re-
use solutions spend on average $880
per barrel of water used compared to
$1020 per barrel of water trucked and
injected into wells although cost com-
parisons are site specific
ldquoFracking has been the Wild West for
the US water industryrdquo said Reese Tis-
dale president of Bluefield Research ina prepared statement ldquoThere are three
reasons for this first there has been
an explosive build-out of fracking well
installations now surpassing 126000
Second there has been a lack of clear
regulation on water management in key
markets And third there is not a one-
size-fits-all treatment solution for frack-
ing meaning solutions providers have
had to ascend a steep learning curve
to treat the variable wastewaters that a
single well is capable of producingrdquo
Tisdale notes that these inhibitors
while still acute are beginning to take on
a new form This is partially due to signifi-
cant gains in water management experi-
ence realized adoption of more efficientwater management strategies among
well operators and the emergence of
new policy mechanisms from regulators
that are playing catch-up with the fast-
moving hydraulic fracturing industry
trendlines
Treatment2
Disposal
6
Supply10
Storage22
Transport60
US $638Billion
S O U R C E B L U E F I E L D R
E S E A R C H
Write in 23 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
Industry-Leading
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1445
New Technique Could ReduceEnergy Required for Oil Refinement
UK scientists have developed a
technique they say has the poten-
tial to dramatically reduce the amount
of energy required for the refinement
of crude oil
Professor Martin Schroumlder and Dr
Sihai Yang from The University of Not-
tingham (wwwnottinghamacuk ) have
led a multi-disciplinary team of scien-
tists from Nottingham the Science and
Technology Facilities Councilrsquos (STFC)
ISIS Neutron Facility Oak Ridge Na-tional Laboratory and Diamond Light
Source to discover a porous material
that works like a chemical sponge to
separate a number of important gases
from mixtures generated during crude
oil refinement
According to a news release from
The University of Nottingham the ex-
isting industrial process uses ldquohuge
amounts of energy to separate and pu-
rify these gases so the new technique
has the potential to revolutionize the oil
industry by significantly reducing car-
bon emissions and making the process
more environmentally friendlyrdquo
Commercially UsefulCrude oil is a raw material that is
refined to produce fuel for cars toheat homes and to create polymers
and other useful materials It is made
up of a complex mixture of hydro-
carbons (chemical compounds that
contain only hydrogen and carbon) of
which certain components are espe-
cially commercially useful
One industrial process used to
achieve hydrocarbon separation is
called ldquocryogenic distillationrdquo which is
widely used worldwide and uses vast
amounts of energy to generate the high
pressures and cryogenic temperatures
required to ensure efficient separation
research amp development
wwwflowcontrolnetworkcom January 2015 | 11
PLASTIC CONTROL VALVES FORALL YOUR CORROSIVE APPLICATIONS
PO Box 938 bull Angleton TX 77516Tel (979) 849-8266 bull wwwcollinsinstcom
Collins plastic control valves are
highly responsive control valves
designed for use with corrosive
media andor corrosive atmos-
pheres
Collins valves feature all-plastic
construction with bodies in PVDF
PP PVC and Halar in various body
styles from 12 - 2 with Globe
Angle or Corner configurations and
many trim sizes and materials
Valves may be furnished without
positioner for ON-OFF applications
Call for more information on our
plastic control valves
Write in 9 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1545
of hydrocarbon mixtures into pure components
However researchers say an innovative solution may
have come in the form of a novel chemical sponge This
porous material a metal-organic framework was devel-
oped by the same team at Nottingham just two years ago
Now in research published in Nature Chemistry for the
first time scientists have proven that it can be used toseparate hydrocarbon mixtures without the need for high
process pressures or very low process temperatures
Reusable MaterialsMade from cheap organic materials aluminum nitrate
salt and water the porous material called NOTT-300 is
able to adsorb different gases found in mixtures of hydro-
carbons at different rates making it possible to sepa-
rate them and extract the most useful ones NOTT-300
requires less energy to function than existing methods
as it operates at ambient temperatures and normal pres-
sures researchers say The gases that are adsorbed intoNOTT-300 can be removed without a significant energy
input and therefore the material can be easily reused
The team of scientists from Nottingham used Diamond
the UKrsquos synchrotron science facility as well as STFCrsquos
ISIS Neutron Facility and Oak Ridge National Laboratory
the UKrsquos and USArsquos world-leading neutron facilities re-
spectively to prove that the sponge works under real-life
conditions
Professor Martin Schroumlder Dean of the Faculty of Sci-
ence at Nottingham said in the news release ldquoIt is a very
important to be able to separate different hydrocarbons ef-
fectively and efficiently with low-energy consumption Po-rous solids such as the metal-organic framework system
studied here represent important materials for the future
development of low-energy separation technologies We
are most grateful to our collaborators at ISIS Neutron Fa-
cility Oak Ridge National Laboratory and Diamond Light
Source in bringing this work to fruitionrdquo
Significant Impact on Oil IndustryDr Sihai Yang the winner of Diamond Young Scientist
and BTM Willis Prize is a Senior Research Fellow at
Nottingham He led the project together with Professor
Martin Schroumlder Yang said ldquoWith the help of advancedcentral facilities like Diamond ISIS and ORNL we have
developed a new separation technique which can poten-
tially reduce the energy usage associated with oil petro-
leum and chemical industries which require the separa-
tion of raw hydrocarbons from crude oil
The discovery of the new material NOTT-300 could
have a significant impact on the oil industry by removing
the necessity for some energy-intensive refinement pro-
cesses researchers say
The research was funded by Engineering and Physical
Sciences Research Council (EPSRC) the European Re-
search Council (ERC) The University of Nottingham andLeverhulme Trust
12 | January 2015
Flow Control Magazine
Write in 21 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
No media contact - No risk of leaks
No process Shut-Downs for installation
No bypass needed
For hazardous area locations (FM approved)
Monitor your Total Acid Consumption
Increase your Plant Up-Time
Balance your Processes
PIOXreg S
PIOXreg S - the evolution of flow and concen-
tration measurement in acid production
Non-intrusive mass flow concen-
tration and density measurement
of aggressive media
wwwpiox-scom
wwwfleximcom
Contact us for a free trial measurement
Thank you for your votes and
making PIOXreg S a Flow Control
Awards Winner
THE OUTLOOK | News amp Notes
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1645
The ASCO trademark is registered in the US and other countries The Emerson logo is a trademark and service mark of Emerson Electric Co copy 2014 ASCO Valve Inc
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 174514 | January 2015 Flow Control Magazine
PPLICATIONS CORNER | Process Instrumentation
This is the final article in a series based on the troubleshoot-
ing of a mysterious unit shutdown due to flowmeter perfor-
mance problems
If yoursquove followed this column for most of 2014 you know
that what should have been a liquid ammonia stream to the
feed plant became problematic due to the occurrence of
bubbles of ammonia gas These bubbles caused an ultrasonic
flowmeter in a unit to indicate zero flow and caused the reactor
to scram (shut down) under warm operating conditions The source of the bubbles was traced back to the pres-
sure drop associated with a control valve located at the
exit of the liquid ammonia tank farm
This issue was resolved by identifying the problem
and fixing it at its source This was a pragmatic ap-
proach at the time (early 1980s) given the operation
of the cooling system in the unit and the limited selec-
tion of applicable flowmeter technologies
By the early 1990s changes were implemented that elim-
inated all process cooling requirementsmdashexcept for the small
jacketed cooler upstream of the liquid ammonia flowmeter In
other words after these changes the entire cooling system
would be operated and maintained to cool a few meters of
one small ammonia pipe Coincidently at about the same
time Coriolis mass flowmeters became more mature and
could reasonably measure the mass flow of liquid streams
with homogeneous low levels of vapor
The convergence of these two events resulted in another
approach to the problem that was not available in the early
1980smdashie install a Coriolis flowmeter that could operate in
the presence of bubbles The purchase and installation of a
Coriolis mass flowmeter was given high priority given its im-pact on unit operation economics and safety (by eliminating
the ldquomidget-makerrdquo (see March 2014 page 14))
Plant requirements and the technology that can meet
plant needs keep changing An excellent solution today can
become outdated in just a few years However there are few
substitutes for understanding fundamentals when addressing
a problem In other words there can be more than one way
to skin a cat FC
wwwspitzerandboyescom
Problem Solved AgainA Coriolis mass flowmeter provides a better solution
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Write in 10 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
David W Spitzer
Ammonia Gas | Coriolis Flowmeter | David W Spitzer | Scram | Troubleshooting
FLOWSTREAM Find related content flowcontrolnetworkcom
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and Boyes
LLC offering engineering seminars strategic marketingconsulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer can be reached at 845 623-
1830 or at wwwspitzerandboyescom
The purchase and installation of a
Coriolis mass flowmeter was given
high priority given its impact on unit
operation economics and safetyldquordquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1845
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1945
Process improvements to increase yield or cut manufactur-
ing costs typically require enhanced process control but the
installed base of measurement instrumentation in a process
plant may simply be unable to facilitate improvements because
of age inadequate performance or unreliability Maintenance
cost and unscheduled process downtime for an aging process
plant can be very damaging to the balance sheet Upgrading
to new more accurate and more reliable instrumentation can
be prohibitively expensive New plant construction must alsomaintain a focus on optimizing costs for the process control
infrastructure The budget approval decision for new plant
construction must weigh such costs against projected market
conditions for the products that the plant is intended to manu-facture In todayrsquos volatile global marketplace return on invest-
ment calculations for plant upgrade or new plant construction
projects may go through several iterations before the trigger is
finally pulled or indeed not pulled
This article describes advances in two-wire instrumenta-
tion specifically in relation to flowmeters that have taken
place in the past few years and the significant cost benefits
that this new technology can realize for plant builders and op-
erators in terms of capital investment and cost of ownership
The Significance of Two-Wire Loop Power
A survey involving 204 participants in the chemical indus-try across Germany Switzerland the UK Canada and the
United States (Manfred Koenig PhD KIM Ludwigshafen
Germany 2006) revealed an 87 percent preference for two-
wire instrumentation versus four-wire in process applications
and 89 percent for utilities This overwhelming preference
may stem from the fact that older process plants were built
with two-wire twisted-pair cable networks connecting all
process units and measuring instruments together in an
overall plant control scheme
However these existing cables are relatively unsophisti-
cated and incapable of supporting anything but low-energy
instrumentation that is insensitive to interference from otherelectrical sources that might be sharing the same cable con-
duit Further the low energy levels supported by these two-
wire loops are more easily rendered safe in terms of explo-
sive risk in hazardous areas containing flammable materials
Many older process plants are also likely to have a significant
installed base of flowmeters employing pre-war (pre-1945)
technology such as positive displacement (PD) turbine vari-
able area (VA or Rotameter) and differential pressure (dP)
Market data firm Flow Research Inc (wwwflowresearch
com) indicates collectively a future compound negative annual
growth rate approaching minus 3 percent to 5 percent for PD
turbine and VA flowmeter types while dP is expected to keeppace with market growth (World Market for Flowmeters 2010)
YSTEMS DESIGN | Flow Measurement
16 | January 2015
Flow Control Magazine
The Two-Wire
ADVANTAGENew wiring options enable modern instrumentsto drive cost savings in existing plant systems
By Steve Milford
Advances in two-wire instrumentation have enabled mod- ern technology to be employed to the advantage of older
plant and process systems
Some chemical manufacturing plants are
competing for survival not only externally
against other global companies but also
internally among the global facilities of theirown company Other industry sectors face
similar challenges
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2045wwwflowcontrolnetworkcom January 2015 | 17
The Need to Replace Older TechnologiesUntil the 21st century two-wire loops were only able
to support these relatively unsophisticated instruments
which convert their measurement by various means into a
4-20mA output or pulse signal to the control system The
more advanced post-war flowmeter technologies such as
Coriolis ultrasonic or electromagnetic flowmeters have
until just eight years ago required a dedicated power sup-
ply for their function in addition to the output loop and
thus a four-wire infrastructure was required as a minimum
Therefore upgrading older two-wire meter devices to moremodern four-wire technology could require significant
expenditure in terms of the installation of separate power
cables and supply modules
There was a major breakthrough in 2006 when a true
two-wire loop-powered inline liquid ultrasonic flowmeter
was introduced (Figure 1) The nature of this breakthrough
was innovation in device power management This was the
missing piece up to that point because to be a true loop-
powered device the meter had to directly provide a full 16
mA span using less than 36 mA of remaining loop current
and less than 1 Watt of electrical energy The flowmeter
operated on a single 4-20 mA HART two-wire loop wasremotely powered by a DC supply was certified Class 1 Divi-
sion 1 and could be deployed as Intrinsically Safe through
the use of an approved safety barrier
A true two-wire loop-powered Coriolis flowmeter followed
in 2011 (Figure 2) employing a new and more advanced
common electronics platform A two-wire loop-powered inline
ultrasonic flowmeter for low-pressure gas was introduced in
2012 and a second two-wire loop-powered Coriolis meter fol-
lowed in 2013 offering improved measurement performance
and an additional high-performance meter tube material
Electromagnetic and vortex flowmeters had already been
available for some years in two-wire loop-powered form butimproved performance resulted as these designs were incor-
COURTESYENDRESS+HAUSER
Figure 1 A two-wire ultrasonic flow- meter released in 2006 operated ona single 4-20 mA two-wire loop
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I I I I LL I
I I I I LL I
copy COPYRIGHT 2015 OMEGA ENGINEERING INC ALL RIGHTS RESERVED
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Prices listed are those in effect at the time of publication and are subject to change without noticePlease contact OMEGArsquos sales department for current prices
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FPD3300 SeriesStarts at
$790
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OSXL-TIM3$999
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Positive Displacement Flow Meterfor Fuels and Oils
bull Aluminum Bodybull FKM Sealsbull Temperatures up to
80ordmC (176ordmF)bull NPT or BSP Threadsbull DIN JIS or ANSI
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Thermal Imaging CameraFor Inspection andFactory Diagnosis
Note Not for ExportUSA Only
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 214518 | January 2015
Flow Control Magazine
porated into their new common electron-
ics platform in 2013 So all the ldquomodernrdquo
flow measurement technologies mdash that
is to say those introduced post-war mdash
have become available as two-wire loop-
powered devices with one exception
namely thermal mass (thermal disper-
sion) meters Unfortunately the power
requirements for this technology exceed
what is currently deemed possible withtwo-wire loop-power management
Payback forTechnology UpgradeConsider a 1rdquo process line
containing a liquid process
ingredient costing $1lb at a
mass flowrate of 150 lbmin-
ute We have $150minute
flowing in the line translating
to $9000hour and $72000
per eight-hour shift That cal-culates further to $360000
per five-day working week and
for a working year of 40 weeks for
example that is $144 million Assume
the existing device is a turbine flowmeter
Now imagine a two-wire loop-
powered Coriolis mass flowmeter is
installed in place of the existing meter
The line would need to be drained and
probably one process flange replaced
allowing the Coriolis to fit mechanically
in place of the turbine However thetwo-wire loop already used for carrying
the existing meterrsquos flow signal to the
control room can be used unaltered
for the complete electrical installation
aspects of the Coriolis flowmeter
The upside of the change is signifi-
cant and clear cut Assuming the exist-
ing meter measurement uncertainty was02 percent of reading then measure-
ment uncertainty improves through use
of Coriolis to 01 percent of reading
giving a 01100 x $14400000 im-
provement in control of the ingredient
annually or $14400 A two-wire Coriolis
mass flowmeter with 01 percent mass
flow accuracy would be paid for in ap-
proximately 6-8 months In practice the
improvement in measurement uncer-
tainty would be greater as the operator
would gain temperature and density in-formation from the Coriolis and the mea-
surement would be devoid of any fluid
property dependence Viscosity change
for example can have a major impact on
turbine meter performance Mechanical
wear and tear that turbine meters even-
tually experience which causes them to
under-register flow is precluded by mod-
ern devices like Coriolis
Furthermore if the process ingredient
was being blended with another then ad-
ditional process improvements could berealized through in-line blending control
using Coriolis technology for final density
as the control point It is possible to have
dual 4-20 mA outputs from two-wire
loop-powered meters but as the main
4-20 mA output representing the prima-
ry variable is also HART then an external
HART Loop Converter or HART IO card in
the control system can provide second-
ary tertiary and quaternary variables as
4-20 mA signals A Coriolis meter is trulya multi-variable device Certain two-wire
devices are also available with Profibus
or Foundation Fieldbus communication
Cutting Wiring CostsIn 2003 WIBEXERA (International
Instrument Usersrsquo Associations) Report
T 2732 X 03 was published and it pro- vided an average survey of prices quoted
in projects at that time for the provision
of power supplies for four-wire instru-
ments The price ranged from euro1200
to euro1800 per instrument depending
upon design and plant characteristics
for an average cost of euro1500 (about
$2000) It would be reasonable to
assume an inflationary factor of 2 per-
cent per annum giving an approximate
current-day figure of $2500
From another source within thechemical industry an estimation of
$40foot to $50foot was given for in-
stallation of four-wire cabling For a
linear 50-foot cable run with for ex-
ample a 10-foot vertical at each end
this equates to $3150 Actual costs
and budget estimates have been given
as high as $10000
The Extent of the Opportunity The modern post-war flow measure-
ment technologies have different powerrequirements and consequently they
are not all available for the
same size range in two-wire
loop-power form For example
two-wire Coriolis flowmeters
are limited to 2rdquo diameter
electromagnetic and inline
low-pressure gas ultrasonics
are limited to 8rdquo and vortex
and inline liquid ultrasonic are
limited to 12rdquo
Nevertheless for thechemical industry in particu-
lar perhaps two-thirds of the
process pipes in a plant will be no larger
than 2rdquo and even when the host process
pipe is larger a correctly sized flowmeter
can still be less than 2rdquo There is consid-
erable scope for two-wire loop-power to
deliver value for flow measurement ap-
plications with total safety
The virtues of Coriolis technology
have been covered but what about
other two-wire technologies An elec-tromagnetic flowmeter in two-wire form
YSTEMS DESIGN | Flow Measurement
In todayrsquos volatile global mar-
ketplace return on investment
calculations for plant upgrade or
new plant construction projects
may go through several itera-
tions before the trigger is finally
pulled or indeed not pulled
ldquo
rdquo
COURTESYENDRESS+HAUSER
Figure 2 Two-wire Coriolis flowme- ters became available in 2011
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2245
can be used on water wastewater or
a light water-based slurry provided the
fluid has around a 20 microSeimenscenti-
metre (microScm) electrical conductivity
A magnetic flowmeter is full bore un-
less flowrates dictate a reduced meter
size in the interests of performance and
so there are no intrusions into the flow
stream and no pressure loss An accu-
racy of 05 percent of reading is normal
from a two-wire magnetic meter and a
modest five diameters (5D) of straight in-let run is needed to avoid error from up-
stream flow disturbances When the fluid
exhibits insufficient conductivity then
the same performance and installation
requirements can be met by an inline ul-
trasonic flowmeter provided the liquid is
essentially clean and bubble-free
For gas or steam applications a vor-
tex meter is the normal choice Using a
built-in temperature sensor a two-wire
loop-powered vortex meter can calculate
mass flow of saturated steam using in-ternal steam tables An external pressure
input allows mass flow of steam to be ac-
curately calculated even when saturated
steam becomes superheated as can oc-
cur downstream of a pressure regulating
valve With mass flow known the vortex
meter can calculate energy and heat flow
A new and exciting development is
the ability of the vortex meter to indicate
wet steam and calculate dryness frac-
tion or steam quality For safety and ef-
ficiency saturated steam should be dry
and free from condensate that is to say
it should possess a high steam quality
factor However the dry or wet state of
saturated steam can sit on a knife-edge
and shift to the opposing state due to
the slightest change in process condi-
tions Rapid and reliable indication of
this change of state is now available
Perhaps the most astonishingachievement in the power management
of two-wire loop-power flowmeters is
that of the ultrasonic biogas meter It is
now possible not only to measure the
flow of wet dirty variable composition
and low-pressure anaerobic digester
gas landfill gas and coal bed methane
gas with a two-wire loop-powered ultra-
sonic flowmeter but also the same de-
vice uses an inbuilt temperature sensor
in combination with measured sound
velocity to calculate methane contentcalorific value and energy flow
Technology to Take UsForwardModern flow technologies provide instru-
ment engineers with vital self-monitoring
information The format of such infor-
mation is easier to understand and act
upon when presented in accordance
with harmonized international guidelines
for online plant asset management eg
NAMUR Standard 107
Continuous plain-text self-diagnostic
and process-related information with
suggested remedies (Figure 3) make it
possible for instrument engineers andoperators to take action at the appro-
priate time mdash immediately or during
the next scheduled shutdown mdash saving
time and money by knowing the exact
health of their measuring point and the
probable actions required to rectify any
abnormal conditions Device verifica-
tion offering third-party validated trace-
ability can be performed on demand ei-
ther locally or remotely from the control
room without the expense of a man in
the field Calibration is then avoided ordeferred without process interruption
Where a process plant has a large
installed base of older mechanical tech-
nologies the decision to embark upon a
program of replacement for plant mod-
ernization cannot of course be taken
easily There are the stocks of spare
parts to consider along with the plant
instrument technicians who are trained
on and at ease with the old devices
However a process plant that retains
the older technology going forward willbe at risk and may find it increasingly
difficult or even impossible to maintain
a cost position that competes effective-
ly in the global market FC
wwwusendresscom
wwwflowcontrolnetworkcom January 2015 | 19
Steve Milford
is a Flow Product
Business Manager
for Endress+Hauser
Inc in Greenwood
Ind He has been
involved in flow
measurement since
1983 and has been
actively involved with standards devel-
opment for flow technology within the
International Standards Organization
(ISO) and the British Standards
Institute Mr Milford can be reached
at stevemilfordusendresscom
Steve Milford
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Coriolis Flowmeter | Magnetic Flowmeter | Two-Wire | Ultrasonic Flowmeter | Vortex Flowmeter
Figure 3 A modern instrumentrsquos display module can provide continuous plain- text self-diagnostic and process-related information
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2345
The bottom line is the volume of gas under one set of
pressure and temperature conditions is not the same as it
would be for the gas under different conditions Why is thisimportant Without compensation for compressibility read-
ings taken by gas flowmeters can result in measurementsmdash
and costs to the buyermdashsignificantly lower or higher than they
should be
The flow of gas in a system can be accounted for and
reported in a number of ways such as by volume by mass
flowrate and by energy Inline turbine meters can offer both
reliability and accuracy in measuring gas flow when matched
with a monitor capable of calculating and displaying results
that have been adjusted for the nature of the gas and impor-
tantly the pressure and temperature
Measuring Flow with an Inline TurbineFlowmeter
With an inline turbine meter gas flows into the meter through
a length of piping that helps to pre-condition the flow by
reducing undesirable swirls and asymmetry Where consid-
ered necessary a flow straightener may even be installed in
line to create a uniform flow profile to the extent possible
As can be seen in Figure 1 a rotor support within the tur-
bine housing further conditions the flow and directs it through
the blades of the rotor High-precision ball bearings allow the
rotor to freely rotate on the shaft
The rotorrsquos rotational speed is directly proportional to the velocity of the fluid passing through the meter The rotor itself
incorporates magnets (or magnetic blades depending on thedesign) while the housing is non-magnetic
A proximity sensor (also known as a pickup coil) is located
in line with the rotor and detects the electrical pulses gener-
ated by the ferrous rotor spinning through the magnetic field
Each pulse represents a discrete volume of gas The out-
put frequency provides the indication of the gas flow rate and
the accumulated pulses over a specified time represent the
total volume of fluid for that measurement period
Need for Calibration The flowrate of the gas through the meter cannot be deter-
mined accurately unless the meter is calibrated The fac-tory calibration determines the meterrsquos constant known
as a K-factor which is then inputted into the gas monitor
PPLICATION NOTES | Flow Measurement
20 | January 2015
Flow Control Magazine
COMPENSATING for
Compressibility inMeasuring Gas Flow Why K-factor adjustment is essential foraccurate inline turbine flow measurement
Unlike crude oil and other liquid fossilfuels natural gas poses a challenge
in monitoring the quantity of gas flowing
through pipelines While liquids do not com-
press gases do and the mass flowrate of
gas being transmitted through gathering
lines depends on both the pressure and
temperature
By Kevin Clark
Figure 1 Internal components of a liquid turbine flowmeter
C O U R T E S Y
T U R B I N E S
I N C
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2445
Wondering Whether the
Pump Guy Seminar
Is for YouCheck out the ldquoPump Guy Insightsrdquo
video series flwctrlcompginsights
PUMP GUY INSIGHT 1NPSHa vs NPSHrmdashWhy all pumps need gauges
PUMP GUY INSIGHT 3How to Operate Your Pump at Best Efficiency
PUMP GUY INSIGHT 5Head vs Flow
PUMP GUY INSIGHT 2 Your Pumps Are Constantly Moving On Their Curves
PUMP GUY INSIGHT 4 The Role of the Pump Reliability Chain
PUMP GUY INSIGHT 6How to Read a Pump Curve
PARTNER SPONSORSFor more information and to register
for upcoming Pump Guy Seminars
visit FlowControlNetworkcomPumpGuy
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2545
PPLICATION NOTES | Flow Measurement
22 | January 2015
Flow Control Magazine
Gas flowmeters measure the actual volume of gas passing
through the meter per minute irrespective of pressure and
temperature1
The volumetric flowrate of a gas is often corrected to
ldquostandardizedrdquo conditions of pressure and temperature While
ldquostandardrdquo conditions can vary depending on the definition
in the US this typically means a pressure of 1473 PSIA(pounds per square inch absolute) and a temperature of 60 F
The flowrate measurement is reported in standard cubic feet
per minute (SCFM)
Compensating for changes in pressure and temperature is
critical Consider a meter system setup for flowing conditions
of 60 PSIG (pounds per square inch gauge) and 60 F and the
line pressure decreases to 50 PSIG while the temperature
remains constant The difference in SCFM between the two
is more than 15 percent which would cost the buyer more
for the gas than it should As Table 1 demonstrates even a
small variation in pressure will result in a surprisingly high er-
ror percentage
Automation of the K-Factor The K-factor is established by an initial factory calibration In
the case of a non-compensated flow monitor any variations
in pressure and temperature will result in manual adjust-
ments needed to the K-factor In order to maintain accurate
flow measurement users must monitor pressure and temper-
ature and make corresponding adjustments to the K-factor To eliminate these manual adjustments some suppliers offer
a flow monitor that automatically adjusts for any changes in
pressure and temperature
These monitors provide accurate flow measurement regard-
less of changing environmental conditions in some cases sup-
porting applications with pressures as high as 15000 PSIG and
temperatures between -350 F to 350 F with a standard accura-
cy of +-1 percent over a flow range of 05 ACFM to 650 ACFM
Final NotesDuring the operation of a flowmeter system the ability to obtain
a readout mdash and to adjust for line pressure and temperaturechanges mdash is sometimes compromised by a lack of electric
power This issue is especially true along gas pipelines in remote
areas To overcome this limitation some manufacturers have
designed low-powered flow monitors which can operate for up
to on year on a single lithium D-cell battery
It is important for users to recognize the effects of the
compressibility of gas As such the quantity of a gas flow-
ing through a gas flowmeter depends on the pressure and
temperature In order to ensure accuracy any flowmetering
system must employ a means to correct for these effects
Otherwise the readout is certain to be in error and could be
unnecessarily costing money This is particularly crucial onwellhead production and in billing scenarios FC
wwwturbinesincorporatedcom
Notations1 The measurement factor in the US is known as the
ACFM actual cubic feet per minute (Metric units are typically
ACMH actual cubic meters per hour)
Table 1 Error induced by line pressure changes
Constant Temperature with Varying Pressure
Pressure Temperature PulsesSCF Error
50 60 2556027821 1546
51 60 2517123288 1370
52 60 2479385307 1199
53 60 2442762186 1034
54 60 240720524 873
55 60 237266858 717
56 60 2339108911 566
57 60 2306485356 418
58 60 2274759285 275
59 60 2243894166 136
60 60 2213855422 000
61 60 2184610304 132
62 60 2156127771 261
63 60 2128378378 386
64 60 210133418 508
65 60 2074968632 627
66 60 2049256506 743
67 60 2024173807 857
68 60 1999697703 967
69 60 1975806452 1075
70 60 1952479339 1181 Flow Measurement | K-Factor | Measurement
Accuracy | Turbine Flowmeter
Find related content flowcontrolnetworkcomhellipSearch on
FLOWSTREAM
Kevin Clark is senior develop-
ment engineer for Turbines Research
amp Development LLC Turbine RampD is a
subsidiary and the research and techni-
cal support arm of Turbines Inc which
serves a range of industries and applica-
tions from oil amp gas to cryogenic liquids
to custody transferKevin Clark
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2645
Pumps Bearings amp Seals TECHNOLOGY REPORT
FEATURES
SYSTEMS DESIGN
The ComplicatedCase of
Compressors
withSide-Streams
24 28 32BEST PRACTICES
How PumpingSystems
AffectSealing
Performance
TECH OUTLOOK
BearingSuppliers
Drive Gains InDeveloping
Markets
wwwflowcontrolnetworkcom January 2015 | 23
S P E C I AL S E C T I O N
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2745
The design and operation of compressors with side-
streams has always been difficult because flow entering the
compressor needs to be mixed with the core flow already
in the compressor (compressed in section-1) in a manner
that does not degrade the aerodynamic performance of sur-
rounding sections Minimizing losses and ensuring proper
mixing of the side-stream flow and core-flow are required to
ensure effective performance of a compressor of this sort
Key considerations for an application involving compres-
sors with side-stream flow include
The plant process typically dictates the side-stream
flange pressure
The impellers upstream of the side-stream should
achieve the necessary pressure for the core-flow
The side-stream flow is typically at a temperature dif-
ferent from compressor core-flow temperature
Process plants need some degree of operational flex-
ibility ie the ability to support variations in core-flow condi-
tions and side-stream conditions
Modern process plants are usually specifying more than
one operating conditions (sometimes two or more manda-
tory conditions) which can present challenges to compres-
sors with side-streams Adding to these issues modern
compressors should operate with much higher impeller tip
The COMPLICATED CASE ofCompressors with Side-StreamsConsidering key system design requirements
to ensure operational efficiency By Amin Almasi
4 January 2015
Flow Control Magazine
|
y
g
Some compressors in certain applications
have one or more incoming side-streams
(or side-loads) that introduce side-stream
flow to mix with the core flow In other words
a radial side-stream inlet is utilized in multi-
impeller centrifugal compressors to introduce
additional gas into the mid-stage of a com-
pressor This design enables optimization in
some process plants However the flow dis-
tribution after the junction of the side-stream
and the main return channel of the upstream
section can significantly affect the perfor-mance of the next section of compressor
In most cases the pressure levels at these
side-streams should be accurately predicted
to meet the theoretical performance
Compressor station at a natural gas processing plant
R U D M E R Z W E R V E R I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2845
speeds and inlet Mach numbers compared to previous
generations of compressor technology
Likewise side-streams are now com-
monly used with medium-sized and
large-sized compressors (eg 1ndash60
MW) The costs associated with cor-
rections on side-stream compres-
sor applicationsmdashany repair
inefficient operation and power
lossesmdashwould be very high Fur-
ther compressors with side-streams
are usually sensitive and difficult
machines to operate In particular
performance curves (performance
pressures efficiency etc) are sen-
sitive to suction inlet conditionsside-stream inlet conditions vol-
ume flow ratio (side-stream vol-
ume to core-flow volume) and side-stream losses
Compressors with side-stream often perform far below
expectations The main reason is that side-stream compres-
sors are different than conventional compressors (without
a side-stream) in design and operation For a compressor
with side-streams tighter tolerances in operating conditions
must be identified and applied Uncontrolled variations of
suction pressure or side-stream pressure are major prob-
lems Another major issue is the variations of the flow ratio
(side-stream flow to core-flow)
Compressor Side-Stream amp Mixing SectionIn many centrifugal compressors the portion of the side-
stream system from the flange connection to the mixing
section is similar to a compressor inlet A great challenge
is ensuring the mixing section provides circumferentially
uniform merged-flow with minimum losses This can be
achieved via effective design of the inlet configuration and
mixing section of the side-stream compressor such that
the impeller can be maintained over the whole operating
range of the compressor In many cases while there are
mixing sections provided for the machine the flows do not
completely mix before entering the impeller of the section-2
(the impeller after the mixing section) Non-uniformity at
inlet flow to the impeller is a key concern for compressor
performance
Another consideration is a compact design of the side-
stream mixing section Specifically a mixing section with
less axial length is always preferred This axial length can af-
fect the compressor rotor dynam-
ics the rotor length and over-
all compressor performance
(design cost operation and
reliability)
The side-stream exit pressure
(side-stream pressure at inlet
of the mixing section) is mainly
a function of the side-stream
flow velocity and the pres-
sure in the previous section of
the compressor Conversely the side-
stream flange pressure can depend on
side-stream flow velocity and section-1
exit conditions Therefore the side-stream
inlet flange volume flow is a function of theflange pressure compressibility (at that
pressure and temperature) and mass flow
Some engineers assume that the side-stream flange pres-
sure is equal to the inlet pressure of the first impeller of the
section-2 This is not true The mixed total pressure can be
estimated on a mass-averaged basis using side-stream total
pressure and return channel exit (section-1) total pressure
In some designs because of the lower static pressure at
the side-stream exit the total pressure at the return channel
exit is lower even though the velocity upstream is roughly
matched for both streams The pressure usually increased
at the returned channel but it can be reduced again at the
side-stream exit While simple in nature this can have an
impact on the prediction of pressure at the side-stream exit
and overall mixing section performance Based on basic flow
principles it was usually assumed that the static pressure
was equal between both flow streams at the mixing location
While this assumption might be used in rough calculations
the accurate simulations have shown this assumption is not
true In fact there are some points (for instance the shroud
wall at the exit of the return channel and the hub wall at
the exit of the side-stream) where this assumption is true
However this is not valid for all locations There are pressure
changes that occur from a side-stream flange to the inlet
of the next section (section-2) which depend on different
factors The first factor is the frictional losses due to side-
stream geometry from side-stream flange to plenum mix-
ing section etc The other factors are pressure changes due
to local curvature and geometry details of mixing section
Another consideration is the operation of a compressor
with side-stream at part-load The performance of the side-
wwwflowcontrolnetworkcom January 2015 25
Figure 1 An example of a centrifugalcompressor with side-stream
COURTESY SIEMENS
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 29456 January 2015
Flow Control Magazine
|
y
g
stream path the mixing section and
the downstream impellers when ma-
chine is operated at part-load or even
off-design operating flows will result
in additional compressor performance
problems In such a case both veloc-
ity profiles and pressure variations in
various parts (side-stream path mixing
section etc) will be different resulting
in complicated flow patterns and com-
plex aerodynamics behaviors
Side-Stream CompressorSectional Performance
Typically vendor-supplied compressor
performance curves reflect flange-to-flange performance because that is
what the plant engineers need to
evaluate the proper operation of their
system (for example from suction to
side-stream and from side-stream to
discharge) In many cases compres-
sor vendors also provide the over-
all compressor performance curves
and performance curves for section-1
(from suction to side-stream) and sec-
tion-2 (from side-stream to discharge)
Flange-to-flange data if not interpret-
ed properly can lead to false conclu-
sions about the relative performance
of individual sections of a compression
system For example if side-stream
losses from the flange to mixing sec-
tion are attributed to the downstream
section (section-2) it will cause the
downstream section (section-2) to
appear low in performance while the
upstream section (section-1) will show
high performance levels
An important behavior to con-
sider is when the actual side-stream
pressure is different than the rated
side-stream pressure When the side-
stream pressure is slightly higher than
the outlet pressure of the section-1
it (section-1) shows a relatively higher
performance compared to the real sec-
tion-1 performance In some cases
the performance of section-1 could be
considerably higher than section-2 In
other words when performance is de-
termined flange to flange the higher
flange pressure is seen as extra ldquopseu-
dordquo work done by the section (since this
is an inconsistent thermodynamic vol-
ume) resulting in a relatively high sec-
tional efficiency (section-1 shows a rel-
atively high efficiency) This is the case
for many compressors with side-stream
because the whole system is designed
(or specifically the side-stream location
is selected) in a way aimed at main-
taining the real side-stream pressure(side-stream inlet) above the section-1
outlet pressure because if the real side-
stream pressure becomes lower than
the section-1 outlet pressure the flow
may (theoretically) reverse
This is particularly important when
the side-stream mass flow is much
lower than the mass flow of core-flow
The above-mentioned reasons explain
why in many simulations calcula-
tions and performance reports related
to compressors with side-stream the
section-1 shows a relatively good ef-
ficiency and section-2 appears low in
efficiency
When the side-stream pressure is
slightly lower than the outlet pressure
of the section-1 the section-1 might
show a relatively lower performance
compared to section-2 This could oc-
cur in some recycle services where the
side-stream is actually a recycle flow
with a mass flow around two to five
times the core-flow The side-stream
(recycle) flow is returned from down-
stream of the compressor to be slightly
compressed and recycled to the down-
stream Such a recycled side-stream
compressor can present unique chal-
lenges for design and operation This
kind of machine usually needs very
special operating procedures and very
fine adjustments regarding operating
pressures and flows
Side-Stream Compressor
Performance amp Operation An important consideration is the sen-
sitivity of compressor overall perfor-
mance curve and sectional perfor-
mance curves to the flow ratio (ratio
of side-stream flow to core-flow) and
to the inlet conditions Variations in
the flow and pressure of the main
suction and side-stream inlet should
be controlled within tight tolerances
For compressors with side-stream the ASME PTC-10 code stipulates limits on
flow ratio (side-stream volume to core-
flow volume) The acceptable variation
in volume flow ratio in a compressor
with a side-stream is +-5 percent as
per ASME PTC code The requested
side-stream pressure tolerance is not
usually specified in compressor codes
but it should be around +- 2 percent
(or sometimes +- 25 percent)
Variance in flow ratio impacts the
velocity levels where the two streams
merge Significant variation in the ve-
locity profile upstream of the impeller
changes the incidence on the blade
leading edge of the following impel-
ler This change in incidence leads to a
change in sectional performance over-
all compressor performance and train
efficiency
If the flow ratio is varied between 95
percent and 105 percent (tolerances
specified in the ASME PTC-10 code)
the flange pressure changes accord-
ingly resulting in a change in the sec-
tional performance and overall perfor-
mance The sectional efficiency varies
sometimes more than +- 4 percent
This variance reduces as the flow is de-
creased toward surge However as the
flow is increased toward overload the
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3045wwwflowcontrolnetworkcom January 2015 27
variance increases up to higher values
(even in some cases three to five times
compared to variations near the surge
zone) For example in a case study
for a compressor with side-streams a
+- 5 percent variation in flow ratio and
associated changes (pressures losses
etc) the sectional efficiency reduced by
approximately 34 percent at the rated
flow at allowable operating points at
the end of curve (near the overload
ie choke) efficiency reduced by ap-
proximately 55 percent These results
show that the variation in sectional
performance and overall performance
due to flow ratio is highest at operat-ing points near the overload and low-
est at operating points near the surge
For compressors which work most of
the time at high flow (flow higher than
rated flow and discharge pressure low-
er than rated pressure) the effects of
flow ratio deviations (and subsequently
efficiency reduction) would be higher
than compressors working on the left-
hand side of curve (say with sufficient
margins near the surge)
In the compressor codes (such as
API 617) the compressor power varia-
tions should be maintained below 4
percent However in some applica-
tions clients require tighter tolerances
on the consumed power sometimes
below 2 percent (or even below 15
percent) Some studies suggest while
+- 5 percent of volume flow ratio is
suitable for performance test as per
ASME PTC-10 code some plants re-
quire tighter control on the consumed
power and compressor performance
(lower limits on the efficiency) the tol-
erances on the volume flow ratio could
be tighter than ASME PTC code In this
regard +- 4 percent tolerance can be
suggested on the volume flow ratio (ra-
tio of side-stream flow to core-flow) of
compressors with side-streams
Based on operational experiences
acceptable variations in volume flow
ratio and inlet pressures (suction inlet
and side-stream inlet) of a compressor
with side-streams are +- 4 percent
and +- 2 percent respectively
Another important consideration is
the required adjustments for the flow
ratio (side-stream flow to core-flow)
Compressors with side-stream usually
require fixed side-stream flange pres-
sures For a compressor with some variations in operation conditions (even
small changes) it is not usually pos-
sible to achieve optimum operation by
keeping the flow ratio (side-stream to
core-flow) constant The flow ratio has
to be adjusted according to the inlet
flow at which the machine is operating
in order to get the required correspond-
ing side-stream flange pressure
Thermal changes have also been
known to cause some instability in
centrifugal compressors An example is
the thermal-induced change of resid-
ual unbalance For compressors with
side-streams which feature tempera-
ture differences between core-flow and
side-stream flow the thermal behav-
ior of the compressor is usually more
complex and requires more attention
Heavy Gas ChallengeHeavy gases (such as heavy hydrocar-
bon gases eg propane propylene
MTBE (Methyl Tertiary Butyl Ether))
have very low gas sonic velocities that
produce high Mach numbers in the
aerodynamic flow paths For these
services because of high Mach num-
ber high flow coefficient stages have
very narrow flow maps characterized
by limited surge and choke margins
Compressors with side-streams in
these services present great challeng-
es This is to say the side-streams and
associated mixing further complicate
design operation and performance
prediction because the pressure tem-
perature and flow conditions at each
one of these side-streams as well
as at the exit of the machine require
stringent tolerances to optimize the
overall efficiency and performance
As such it is important to accuratelymodel design operate and moni-
tor performance characteristics of any
impellers diffusers return channels
and generally all flow-path components
in a compressor with side-stream FC
Amin Almasi
is a senior rotating
machine consultant
in Australia He is
a chartered profes- sional engineer of
Engineers Australia
(MIEAust CPEng ndash
Mechanical) and
IMechE (CEng MIMechE) holds
bachelorrsquos and masterrsquos degrees
in Mechanical Engineering and is
a registered professional engineer
in Queensland He specializes in
rotating machines including cen-
trifugal screw and reciprocating
compressors gas turbines steamturbines engines pumps subsea
offshore rotating machines LNG
units condition monitoring and reli-
ability Mr Almasi is an active mem-
ber of Engineers Australia IMechE
ASME and SPE He can be reached
at aminalmasiymailcom
Amin Almasi
Compressor | Gas Flow | Performance Curve | Side-Stream Flow
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3145
The pressure in the stuffing box
containing the packing can be estimat-
ed by the following equation
SBP = [Discharge ndash Suction] 3 + Suction
Pressure at the bottom of the stuff-
ing box will be higher than the suction
pressure but considerably lower than
the discharge pressure It should be
noted this calculation will yield a con-
servative estimate of stuffing box pres-
sure that can be further reduced by
pump design
A hole in the stuffing box serves as
a port for injecting clean fluid that cir-
culates around a lantern ring aligned
under the flush port The fluid flushes
solids back into the process to protect
the packing from abrasive wear If the
clean fluid is injected at a pressure ex-
ceeding that at the bottom of the stuff-
ing box some of it will leak back into
the process and some will leak out to
the atmosphere Recommended flush
injection pressure is 15ndash30 PSI (1ndash2
Bar) greater than the pressure at the
bottom of the stuffing box
Fluid injection is also used to lubri-
cate and cool dry-running packing that
is subject to frictional heat and to pre-
vent air from entering the pump which
reduces flow and operating efficiency
Centrifugal pumps utilize three
types of impellersmdashopen semi-open
and closed (Figures 2 3 amp 4) Open
designs prevent fluids with large solids
from clogging the impellers but at theexpense of pump efficiency Backing
plates on semi-open designs serve to
trap the fluid for more efficient opera-
tion Closed impellers are for use with
clean fluids since solids could ac-
cumulate in the eye which would re-
quire tearing down the pump to remove
them
Single-Stage CentrifugalPumpsSingle-stage centrifugal pumps typi-
cally have good bearing support of the
shaft with few run-out or ldquowhiprdquo prob-
lems However in some cases they
are subject to cavitation This occurs
in the eye of the impeller where the
fluid is under vacuum If the pressure
is low enough it will cause the material
to vaporize forming air or water vapor
bubbles As the fluid passes through
How Pumping Systems Design Affects Sealing Performance
By Chris Boss
8 January 2015
Flow Control Magazine
|
Understanding how different types of pump designs impact
sealing is critical to optimizing efficiency safety and lon-
gevity of the sealing system Used for a wide variety of media
including clear fluids solutions and slurries single-stage
centrifugal pumps are one of the most common
types (Figure 1) Fluid drawn into these pumps
enters the eye of an impeller that spins itto the outside of its container
or volute building pressure as
it moves toward discharge
Some of this fluid will work
its way behind the impeller
where it must be sealed with
compression packing or a
mechanical seal
Figure 1
Figure 2 Figure 3 Figure 4
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3245
the pump under increasing pressure
these bubbles implode sending shock
and vibration through the impeller
adversely affecting the seal This phe-
nomenon can be mitigated by running
the pump at slower speed and higher
pressure at the suction end to prevent
air from entering the fluid
Double-Ended Split-CasePumpsOperating on the same centrifugal prin-
ciple but slightly different geometry are
double-ended split-case pumps (Figure
5) Fluid enters both ends of the pump
and is directed into the eye of an impel-ler which spins it out of the volute to
discharge Packing is installed on both
the shaft and bearing ends so the stuff-
ing box is exposed only to suction pres-
sure which is usually quite low
Axial Flow Pumps Axial flow pumps operate like hydro
turbines in reverse whereby a propeller
(or axial impeller) pushes the fluid to
discharge (Figure 6)
Since the stuffing box is located
downstream of the propeller at the dis-
charge end of the pump the packing is
exposed to the full discharge pressure
Vertical PumpsVertical turbine pumps are typically
flange-mounted on a floor extending
downward into a water-filled sump
hole (Figure 7) Available as single- or
multi-stage pumps they feature an
impeller or series of impellers rotated
simultaneously by a single shaft The
impellers increase the pressure of the
upward flow subjecting the stuffing box
to full discharge pressure
Vertical pumps can be quite long so
inadequate bearing support can cause
the shaft to run out This can induce
undesirable lateral motion on the pack-
ing Worse the packing may be forced
to serve both as a bearing and a seal To
withstand these conditions the packing
should be resilient elastic and resistant
to deformation These properties rule
out packing such as graphite foil in favor
of fiber-based materials
Multi-Stage PumpsMulti-stage pumps are used for high-
pressure applications such as feeding
the boilers in steam-powered generating
plants Stuffing box pressure can vary
with pump design and number of stag-
es Designed for clean fluids and high
operating speeds these pumps typically
have high- and low-pressure ends with ahydraulic pressure equalization line run-
ning between the stuffing boxes
Like vertical pumps multi-stage
pumps feature a series of impellers to
build fluid discharge pressure In the
case of the six-stage pump pictured in
Figure 8 fluid enters at the drive end
where a stuffing box is exposed to suc-
tion pressure Channeled from one
impeller to the next through the pump
casting the fluid can reach extremely
high pressures at discharge
A second stuffing box located at the
bearing end is exposed to an intermedi-
ate pressure from the third impeller This
pressure is greater than the suction pres-
sure but much less than the discharge
pressure which can reach 2000 PSI
Fortunately the stuffing boxes in
these pumps are not exposed to dis-
charge pressures and typically see be-
low 500 PSI which is within the range
of some packing materials
wwwflowcontrolnetworkcom January 2015 29
Figure 5
Figure 6
Figure 7
Figure 8
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 33450 January 2015
Flow Control Magazine
| Gear PumpsPositive-displacement or gear pumps
operate on a different principle than
centrifugal pumps In external gear
pumps the fluid flows around the out-
side of the gears the intermeshing
of which forces it through the pump
to discharge (Figure 9) This design
makes these pumps particularly suit-
able for use with highly viscous fluids
such as resins emulsions syrups and
adhesives As such they are used for
transfer or metering applications
It should be noted gear pumps will
continue to displace fluid as long as
their shafts are turning which can pose
a problem if a clog occurs at the dis-
charge The resulting buildup of pres-
sure can blow out seals and damage
the pump Therefore most gear pumps
have pressure relief valves to divert
fluid back to the suction side for re-
circulation through the pump Internal
gear pumps operate slightly differently
but also have pressure relief valves to
prevent damage from excessive pres-
sure (Figure 10) In both external and
internal gear pumps the maximum
stuffing box pressure is determined by
these valves
Other rotating equipment includes
mixersagitators which are similar to
pumps in terms of the speeds to which
the packing is exposed There are ba-
sically three types of mixersagitators
top- bottom- and side-entry Top-entry
models are subject to the same con-
cerns about shaft run-out ldquowhiprdquo and
lateral forces on the paddles that are
encountered in some vertical pumps
Although some fluid may splash onto
the packing these mixers basically run
dry so the packing must have the abil-
ity to dissipate the resulting frictional
heat
In bottom-entry mixers the packing
is always exposed to fluid and may also
be exposed to solids requiring abra-
sion-resistance If the seal fails the en-
tire contents of the tank will eventually
drain out onto the bearings the floor
and other components under the stuff-
ing box
The packing in side-entry mixers may
be fully or intermittently exposed to flu-
id as well as side loading and vibration
Aside from media temperature
speed and other application variables
the configurations and operating prin-
ciples of rotary-type pumps exert differ-
ent forces on the seals used to keep
them from leaking These forces can
spell the difference between accept-
able seal performance and failure
Understanding these differences has
important implications that should be
taken into account to assure proper
sealing selection for long-term trou-
ble-free performance FC
wwwgarlockcom
Chris Boss is
a senior applica-
tions engineer for
Garlock Sealing
Technologies in
Palmyra NY He
has held various
positions in produc-
tion engineering
product development and applica-
tions engineering for the companyrsquos
compression packing division He
is a BSME graduate of the State
University of New York at Buffalo Mr
Boss can be reached at 800 448-
6688 or chrisbossgarlockcom
Chris Boss
Cavitation | Centrifugal Pump | Pump Packing | Sealing System
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Figure 9
Figure 10
Aside from media temperature speed and
other application variables the configurations
and operating principles of rotary-type
pumps exert different forces on the seals used
to keep them from leaking These forces can
spell the difference between acceptable seal
performance and failure
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3445
NS IDERNDUSTRIAL AUTOMATION + PROCESS CONTROL
WANT
INFORMATION
ON THE
automationindustry
SUBSCRIBE NOW at wwwiainsidercouk
Published by Spitzer and Boyes LLC Write in 15 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3545
Frost says the push from developing
economies is important as the market
is technologically mature and seeing
restricted growth in developed econo-
mies This is particularly true in Europe
and North America where recent finan-
cial insta-
bility has
reduced capital expenditure across end-
user industries
Bill Moore senior vice president of
sales development and channel man-
agement for global bearings manufac-
turer SKF says ldquosmartrdquo products and
the expansion of robust reliability pro-
grams are helping to drive new invest-
ment particularly in developed coun-
tries where the cost to compete is
high Frost says the magnitude of
the existing global installed base will
strengthen the need for replacement
and upgrades adding to market de-
mand as well
Frost says despite the potential
in developing economies the focus
on price as a product differentiator
may lead to intense price pressures
among manufacturers and bring down
the value of the overall market in the
short term The growing trend among
consumers to choose low-cost Chinese
imports will complicate this challenge
As price and quality become stan-
dardized across the globe customers
will base more of their purchasing deci-
sions on value-added services accord-
ing to Frost This will push manufactur-
ers to create more maintenance-free
solutions such as lubrication-free
bearings that offer end-users savings
on service and replacement costs and
reduce downtimeldquoOffering a complete line of prod-
ucts with comprehensive services will
be another feather in the cap of ven-
dors looking to widen their consumer
baserdquo notes Frost Industrial Automa-
tion and Process Control Research
Analyst Guru Mahesh
Moore says the trend of outsourcing
manufacturing to regions where labor
and production costs are favorable is
becoming less of a factor
ldquoThe days when cheap labor made
a significant difference in where a prod-
uct is manufactured mdash particularly high
value-added products or high weight
and bulk products mdash are coming to
an end as the cost of transportation
storage and inventory balance out the
benefits of production costs where la-
bor is a smaller percentage of the cost
of manufacturingrdquo Moore says ldquoLocal
manufacturing development will indeed
come to developing countries as their
ability to create markets that generate
economies of scale that support local
production is a clear trend and one that
all manufacturers will pay attention tordquo
Moore says that development of
maintenance-free or predictive tech-
nologies and products will be a sig-
nificant advantage to everyone in the
Bearing amp Coupling Manufacturers Focus
onDEVELOPING Economies
amp EFFICIENCY InnovationBy Amy W Richardson
2 January 2015
Flow Control Magazine
|
gy
Anew study from Frost amp Sullivan (wwwfrostcom) fore-
casts steady growth for the overall bearings and couplings
market based on rapid industrial development in high-growth
regions Specifically Frost predicts development in Mexico
Indonesia Nigeria Turkey Brazil Russia India and Chinawill help boost the bearings amp couplings market from $2206
billion in 2013 to an estimated $2676 billion in 2018
The development of maintenance-freeor predictive technologies will helpboost growth in the bearings market For example SKF is developing products that will automatically notifyusers when a bearing or mechanicalrotating component is approachingthe end of its useful life Pictured hereis an SKF Microlog analyzer a por- table condition monitoring tool
COURTESY SKF
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
improved productivity through simplified solutions The powerful technology and tools ensure repeatable
reliable accurate measurements Easier access to process data allows for better troubleshooting process
optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
For daily product notes visit the lsquoFeatured Productsrsquo section flowcontrolnetworkcom
ON THE WEB
1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3845
FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
and benefits as well as grids of
instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
services provided for the
mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
Brought to you by Beamex
Your Source For Fluid Handling Videos
Go towwwflowcontrolnetworkcomfreeinfo
Select appropriate issue ofFlow Control Magazine
Select advertisements thatinterest you
Enter your email amp clickldquoSubmit Requestrdquo
1
2
3
4
PRODUCT
INFORMATION
ONLINE
Follow these 4 steps to receive freeproduct information from suppliers
FREE
FEATURED VIDEO How to Calibrate aPressure Measurement Loop
For more information about FlowTube
sponsor packs email FlowControlGrandViewMediacom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4245
THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
Name ________________________________________________________________
Title _________________________________________________________________
Company _____________________________________________________________
AddressCityStateZip __________________________________________________
______________________________________________________________________
Phone ________________________________________________________________
E-Mail ________________________________________________________________
One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545
![Page 2: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/2.jpg)
7232019 Flow Control January 2015
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Twitterfollow Flow Control on Twitter
Google+connect with Flow Control on Google+
E-Newsget e-mail updates from Flow Control
Advertisefind out how Flow Control can help market
your products amp services
Connect
LinkedIn join Flow Controlrsquos LinkedIn group
Facebookbecome a Flow Control Facebook fan
FlowTubeFlow Controlrsquos fluid handling video archive
Subscribereceive the print or digital edition
of Flow Control
reg
SOLUTIONS FOR FLUID MOVEMENT MEASUREMENT amp CONTAINMENT
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 345
The only press fittings in multiple materials
The g lobal leader
in plumbing heat ingand p ipe jo in ing systems
Industrial press fitting solutionsfor clean controlled installations
Do more with Viega press fitting solutions
for hundreds of applications Make the
same press connections for copper
stainless and black iron along with
easy-to-install transition fittings
Only Viega can provide all of your system
installation needs Viega connections can
be made in seconds wet or dry so lengthy
shutdowns become a thing of the past
and system maintenance and repair is
easier than ever Whatever your industrial
installation needs Viega has the answers
bull Only Viega offers the patented
Smart Connectreg feature toidentify unpressed connections
bull More than 1400 tting choices
in copper stainless and carbon steel
bull Viega ProPressreg and Viega MegaPressreg
fittings have been tested to the strictest
standards in North America
bull Viega MegaPress the only carbon steel
press solution for water and gas
bull No ame is required to install Viega
products eliminating noxious fumes
hot work permits and fire watches
wwwviegaus | 1-800-976-9819
Write in 1 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 445
Do you need flow measurement with online density compensation
Available now with OPTISWIRL 4200 from KROHNE
Featuring integrated pressure and temperature sensors the new OPTISWIRL 4200
vortex flowmeter provides online density compensation for all types of gas and steam
The OPTISWIRL 4200 even masters fluctuating operating conditions with effortless
precision and helps to significantly reduce installation costs Itrsquos the smart choice for
auxiliary and supply processes in a broad range of applications
Developed for use in continuous volume flow measurements in safety-related
applications the OPTISWIRL 4200 is in full compliance with the IEC 61508 SIL2 safety
standard Units can be easily switched from non-SIL mode to SIL mode without the need
to call out a service technician
Minimising downtime is critical for your business Thatrsquos why the OPTISWIRL 4200
provides redundant data storage of all calibration and configuration data in the display
memory and the electronics module ndash transferring data to replacement modules is a snap
When efficiency and flexibility matter most the OPTISWIRL 4200 is the definitive choice
KROHNE ndash Flow measurement is our world
Please see our website for more information
The All-in-OneSolution
Write in 2 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 545
featurescontents
16 The Two-Wire Advantage
By Steve Milford Advances in two-wire instrumentation specifically in relation to flow-
meters have enabled significant cost benefits for new technology in-
stallations in terms of capital investment and cost of ownership
20 Compensating for CompressibilityIn Gas Flow MeasurementBy Kevin Clark
K-factor adjustment is a key factor in ensuring accurate gas flow mea-
surement for inline turbine meters The K-factor is established by an
initial factory calibration In the case of a non-compensated flow moni-
tor any variations in pressure and temperature will require manual
adjustments to the K-factor
2 | January 2015 Flow Control Magazine
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 qualied subscribers Non-qualied subscrip-
tion rates in the US 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 t he Circulation
Manager for more wire transfer information Single copies $10
per issue in the US and Canada Single copies $15 per is-
sue in all other countries All subscription payments are due in
US funds
POSTMASTER Send address changes to Flow Control PO BOX
2174 Skokie IL 60076-7874 Periodical postage rates paid at
Subscription Information Toll Free 8667214807Outside US 8477631867Mail PO Box 2174Skokie IL 60076-7874E-mail flowcontrolhalldatacom
SubscribeRenewChange of Addresswwwflowcontrolnetworkcomsubscribe
Birmingham AL 35242 and additional mailing ofces
copy Entire contents copyright 2015 No portion of this publica-
tion may be reproduced in any form without written permis-
sion of the publisher Views expressed by the bylined con-
tributors should not be construed as reecting the opinion
of this publication Publication of productservice information
should not be deemed as a recommendation by the publisher
Editorial contributions are accepted from the uid handling
industry Contact the editor for details Productservice infor-
mation 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
1 616
Pumps Bearings amp Seals Technology Report SPECIAL SECTION PAGE 23
24 The Complicated Case of Compressors
with Side-StreamsBy Amin Almasi
28 How Pumping Systems Design AffectsSealing PerformanceBy Chris Boss
32
Bearings amp Couplings Suppliers Position
to Drive Market GrowthBy Amy W Richardson
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 645
Do you know whatrsquos
gone out the window
at your facility
Magnetrolreg energy management solutions monitor and measure the energyflowing through your facility to reduce utility costs and make processes moreefficient Easy to install and operate TA2 thermal flow meters provide you withan efficient environmentally responsible way to manage compressed air andnatural gas cost centers
Make MAGNETROL Thermatel reg TA2 mass flowmeters part of your energy management strategyVisit magnetrolcomthermalmassflow or contact
your MAGNETROL representative for more information
Measure and control your compressed
air and natural gas energy costs with
Thermatelreg TA2
991266 PDJQHWUROFRP Write in 3 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 745
1 9 9 5 - 2 0 1
51 9 9 5 - 2 0 1
5
20th20th january 2015 | Vol XXI No 1
4 | January 2015
Flow Control Magazine
departmentscolumns6 EDITORrsquoS FILE
4 flow things you need to know aboutthis month
14 APPLICATIONS CORNERa coriolis mass flowmeter providesa better solution
39 WORD SEARCH temperature measurement
40 QUIZ CORNER how to calculate orifice plate flow rate
Cover imagesFlowmetercourtesyEndress+HauserBackgroundiStock
8 NEWS amp NOTES api 624 valveemissions update intelligent features toboost desal pumps market hydraulic fractur-ing water treatment on the rise
34 UP CLOSE with Micro Motionrsquos Model5700 Coriolis Transmitter
35 NEW PRODUCTS
36 WEB RESOURCE FILE
38 ADPRODUCT INDEX
S I N C E 1 9 5 8
Itrsquos More than a Check Valve
Itrsquos a Check-All
When You Need Absolute Precision
CHECK-ALL IS THE ONLY CHOICE
Our spring loaded check valves are assembled
to your exact needs ensuring absolute precision
and reliability They work like they should Plus
most lead times are less than one week Thatrsquos
what makes Check-All the only choice
Get me a Check-AllManufactured in
West Des Moines Iowa USA515-224-2301 bull salescheckallcom bull wwwcheckallcom
Write in 4 or Request Info Ins tantly at wwwFlowControlNetworkcomfreeinfo Write in 5 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
Return on investment calculations for plant upgrade or new
plant construction projects may go through several iterationsbefore the trigger is finally pulled or indeed not pulledldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 845
The new Ultratrade 8c The capability and performance
your market demands
Copyright copy FMC Technologies Inc All Rights Reserved
FMC Technologiesrsquo Ultra 8c ultrasonic owmeter shares the advanced technology
of the next generation Smith Meterreg Ultra Series meters With its touchscreen
interface upgradable memory and high-speed processor the Ultra 8c provides
cutting-edge performance and diagnostic ability And with additional measurement
paths the Ultra 8c has even better cross-ow and swirl compensation for improved
accuracy and repeatability Whether for leak detection or custody transfer theUltra 8c gives you the assurance of superior performance in the eld even for the
most viscous crude oils in todayrsquos market
For more information visit wwwfmctechnologiescomultrafc
wwwfmctechnologiescom
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 945
20 Years of Flow Control This
year marks the 20th Anniversary of
Flow Control magazine Launched
in 1995 with the aim of serving technical
professionals involved with designing oper-
ating and maintaining fluid handling systems in a wide range of
industries Flow Control has leveraged its many years of experi-
ence to establish a unique niche and reputation for providinghigh-quality information to you our subscribers I congratulate everybody who helped
Flow Control get to where it stands today Herersquos to another 20 years of success
Training Time Itrsquos a new year and we have two new
training opportunities for
you to enhance your skillset in 2015
Regular Flow Control columnists Da-
vid W Spitzer and Larry Bachus will
be presenting three-day courses on
Flow Measurement and Pumping
Systems respectively I encourage you and your colleagues to take ad-
vantage of these important training
opportunities For more details see
flwctrlcomflowseminar amp
flwctrlcompumpguy
Oil amp Gas Gender Gap Results of a
new global workforce survey conduct-
ed by OilCareerscom and Air Energi
show a gender gap in the oil amp gas industry
persists despite ongoing efforts to recruit more
women into the industry According to hiring
managers the
top three factors
that significantlycontributed to
the gender gap
in the oil amp gas
industry are
1 A lack of women entering the industry (55
percent)
2 An industry culture created by a male-domi-nated environment (53 percent)
3 The logistics requirement ie travel shift
and working patterns in the field (30 percent)
For more on this story and an infographic seeflwctrlcomog_gendergap
Rockwell Automation Fair 2014 Our colleagueKevin Parker at Processing magazine attended the
annual Rockwell Automation Fair Nov 9-10 in
Anaheim Calif Parker gleaned some interesting perspec-
tive on key trends in process automation including
1 Hardware and software are more blended than ever
2 Fog computing (a kind of cloud computing) is making
headway in industrial engineering environments where latency is a critical concern
For Parkerrsquos full report from the Automation Fair see flwctrlcomrockwellfair2014
DITORrsquoS FILE
6 | January 2015
Flow Control Magazine
4 Flow Things You Need to Know
GROUP PUBLISHERPROCESSINGFLOW CONTROL
MICHAEL C CHRISTIAN | (908) 507-5472mikecgrandviewmediacom
NATIONAL ACCOUNTS MANAGERJIM SEMPLE | (908) 963-3008 jsemplegrandviewmediacom
EXECUTIVE DIRECTOR OF CONTENTMATT MIGLIORE | (610) 828-1711
mattgrandviewmediacom
MANAGING EDITOR AMY W RICHARDSON | (205) 408-5050
arichardsongrandviewmediacom
COLUMNISTS
LARRY BACHUSDAVID W SPITZER JESSE YODER
ART DIRECTORJULIE FLYNN
juliegrandviewmediacom
MANAGER - DIGITAL OPERATIONSMARY BETH ROMANO
SUBSCRIPTION amp REPRINT REQUESTSflowcontrolhalldatacom
Administrative TeamGENERAL MANAGER
BARRY LOVETTE
CHIEF OPERATIONS OFFICERBRENT KIZZIRE
VICE PRESIDENT OF FINANCEBRAD YOUNGBLOOD
VICE PRESSIDENT OF B2B GROUPMIKE WASSON
CHIEF REVENUE OFFICERCHRIS DOLAN
VP AUDIENCE DEVELOPMENTDELICIA POOLE
AUDIENCE DEVELOPMENT MANAGER ANNA HICKS
DIGITAL AUDIENCEDEVELOPMENT ANALYST
STACY BARNES
EDITORIAL ADVISORY BOARDLarry Bachus Bachus Company IncGary Cornell Blacoh Fluid Control
Jeff Jennings Equilibar LLCMitch Johnson JMS SoutheastPeter Kucmas Elster Instromet
Jim Lauria Water Technology Executive
John Merrill PE EagleBurgmann IndustriesSteve Milford Endress+Hauser US Tom OrsquoBanion Emerson Process
Management Micro MotionDavid W Spitzer PE Spitzer and Boyes LLC
Tom Tschanz McIlvaine Company John C Tverberg Metals and Materials
Consulting EngineersJesse Yoder PhD Flow Research Inc
WINNER
WINNER WINNER
PERSPECTIVES FROM THE MONTH THAT WAS IN THE WORLD OF FLOW CONTROL
WINNER WINNER
THE
NETWORK
1
2 3
4
1 9 9 5 - 2 0
1 51 9 9 5
- 2 0 1 5
20th20th
Matt Migliore Executive Director of Content MattGrandViewMediacom
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1045
Endress+Hauser Inc
2350 Endress Place
Greenwood IN 46143
infousendresscom
ww wusendresscom
Sales 888-ENDRESS
Service 800-642-8737
Fax 317-535-8498
Guided wave radar level products - built for safety precision and efficiency
bull Reliable non-contact measurement even for changing process conditions
bull HistoROMreg data management - concept for fast and easy
commissioning maintenance and diagnostics
bull Multi-Echo Tracking evaluation - highest reliability even with the
presence of obstructions in the vessel
bull Hardware and software developed according to IEC61508 up to SIL3(in homogeneous redundancy)
bull Seamless integration into control or asset management systems
bull Worldrsquos easiest proof test concept for SIL saves time and cost
wwwusendresscommicropilot-radar-level
The newest generation of Micropilot
Taking your process to the next level
Write in 7 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1145
HE OUTLOOK | News amp Notes
1 ISO15848 ldquoMeasurement test and qualification proce-
dures for fugitive emissionsrdquo
a Part I ndash ldquoClassification system and qualification proce-dures for type testing of valvesrdquo
b Part II ndash ldquoProduction acceptance test of valvesrdquo
2 API 622 ldquoType Testing of Process Valve Packing for Fugitive
Emissionsrdquo
3 End-user defined fugitive emission reduction requirements
Key aspects of valve testing per API 624 include
The standard covers rising and rising-rotating stem
valves up to 24rdquo diameter
Class 1500 valves are not covered
The test medium is methane
310 test cycles are required with three thermal cycles Temperature application range is from -29 C to 538 C
with last cycle 10 cycles user-defined (can be -45 C)
Re-tightening of gland bolts is not permitted during test
Valve stem test orientation is vertical
Several valves must be tested to achieve API 624 com-
pliance Similar industry principles applied to test valves
qualify two nominal sizes smaller one size larger and one
pressure class below
Allowable leakage is 100 PPM maximum
Gate and globe valves need to be tested separately
For example Gate Valves per API602 four tests API600
eight tests (up to 20rdquo diameter) API 603 eight tests andfor Globe Valves per API 602 four tests
Test valves should be production valves not specially
manufactured test valves
As a result of the release of API 624 testing companies have
been gearing up for an increase in the number and size of
test valves and new test houses are coming to market Withthis in mind implementation of API 624 needs to be carefully
monitored and claims from valve manufacturers should be
validated by requesting to view test results Important factors
to be mindful of include
Number of cycles on some valves could be detrimental
to packing as certain smaller size valves donrsquot come with
grease ports to keep the stem lubricated all of the time
Test failures of valve stem threads yokes and glands
Grease traps into packing and causes leakage
At higher temperatures a few greases create volatile
organic compound and burn off
Testing in vertical generates more heat in yoke area
Certain challenges need a good testing company that has
experience in testing on fugitive emissions and provides
guidelines to manufacturers in terms of use of packing valve
grease testing requirements etc
A preliminary survey was conducted with end-users regard-
ing current utilization and application of API 624 For a sum-
mary of responses from this survey visit flwctrlcom1oWijWz
Gobind Khiani PEng is with Fluor Canada Ltd Khiani has
spent 20-plus years in the energy and power business and 10-
plus years in the Western Canadian oil and gas industry Hecan be reached at 403 850-6982 or gobindkhianifluorcom
Valve Standards UpdateEnd-users ramp up compliance efforts for API 624
as new specifications emerge on the horizon
8 | January 2015
Flow Control Magazine
By Gobind Khiani
In the May 2014 issue of Flow Control (page
16) the new standard API 624 ldquoType Testing
of Rising Stem Valves Equipped with Graphite
Packing for Fugitive Emissions First Editionrdquo was
addressed This standard which was published
and put into effect in February 2014 estab-
lishes guidelines for testing industrial valves for
emissions compliance Since the publication ofthe May article further requests from industry
have spurred the creation of another specifi-
cation API 641 ldquoType Testing of Quarter-Turn
Valvesrdquo and an API ldquoPiping and Valvesrdquo commit-
tee has been formed Regulators and end-users
are also working on
1992 1998 2003 2008 2013 2020
4
35
3
25
2
15
1
05
0
M i l l i o n o f
t o n n e s y e a r Will API 624
have a stepeffect in reducing
fugitiveemissions
Global valve fugitive emissions
End User response at best
End User response actual
S O U R C E G O B I N D K
H I A N I
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1245
Intelligent Features to Boost Global WaterDesalination Pumps Market
The Global Water Desalination
Pumps Market is expected to grow
at a CAGR of 77 percent from 2015 to
2019 according to a new report from
TechNavio (wwwtechnaviocom)
The report shows demand for water
treatment has increased significantly in
developing countries where fresh wa-
ter resources can be scarce Providing
clean and potable water to huge popu-
lations has become a priority which is
pushing the demand for water desalina-tion pumps in the market according to
TechNavio
The report emphasizes the emer-
gence of intelligent pump systems as
a major driver of market growth In-
telligent pumps possess the ability to
regulate flow and pressure and these
systems can automatically adjust to
process and pump system changes
ldquoIntelligent pump systems are be-
ing adopted by many manufacturers
because of the high level of fault toler-
ance ability which leads to a significant
reduction in the total cost of owner-
shiprdquo said Faisal Ghaus vice president
of TechNavio in a news release ldquoThe
adoption of these systems will also
help industries comply with current Eu-
ropean Union regulations in relation toreduction in energy consumptionrdquo
The growing demand for clean wa-
ter worldwide will continue to augment
the demand for water desalination sys-
tems which will propel the Global Water
Desalination Pumps Market during the
forecast period
trendlines
wwwflowcontrolnetworkcom January 2015 | 9
Write in 8 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
Intelligent pump sys-tems are being adopt-
ed by many manufac-
turers because of the
high level of fault tol-
erance ability which
leads to a significant
reduction in the total
cost of ownership
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1345
HE OUTLOOK | News amp Notes
10 | January 2015
Flow Control Magazine
Hydraulic Fracturing WaterTreatment amp Reuse Expected to Soar
Wastewater treatment spending for
hydraulic fracturing is expected to
grow almost three-fold from $138 mil-
lion in 2014 to $357 million in 2020 in
the US according to a new report from
Bluefield Research
The US hydraulic fracturing industry
consumes over 1 billion barrels of wa-
ter annually producing 450ndash500 mil-
lion barrels of contaminated water for
disposal with only about 14 percent
treated and reused Bluefield cites watersupplies increasingly at risk tighter regu-
lations emerging in key states and costs
of disposal on the rise as factors con-
tributing to the substantial rise in water
treatment and reuse which is expected
to account for 27 percent of total pro-
duced and flowback water by 2020
Overall the US hydraulic fracturing
industry will spend $638 billion in 2014
on water management Water transport
and disposal costs will account for 66
percent of the total water managementspent this year with treatment compris-
ing roughly 2 percent
Bluefield reports water scarcity in
Western US states has had little im-
pact to date on fracturing water supply
but that is likely to change if droughts
persist Meanwhile state regulators are
beginning to tighten control of produced
water disposal In Pennsylvania where
policymakers in 2010 placed discharge
limits on wastewater from unconven-
tional oil amp gas operations statewide
treatment and reuse rates for the Mar-
cellus jumped to 90 percent in 2014
The increasing cost of transport and
injecting water into wells mdash now ac-
counting for 66 percent of water servicesspending mdash and the improving cost
structures of treatment provide another
driver of reuse Bluefield reports Well
operators that employ treatment and re-
use solutions spend on average $880
per barrel of water used compared to
$1020 per barrel of water trucked and
injected into wells although cost com-
parisons are site specific
ldquoFracking has been the Wild West for
the US water industryrdquo said Reese Tis-
dale president of Bluefield Research ina prepared statement ldquoThere are three
reasons for this first there has been
an explosive build-out of fracking well
installations now surpassing 126000
Second there has been a lack of clear
regulation on water management in key
markets And third there is not a one-
size-fits-all treatment solution for frack-
ing meaning solutions providers have
had to ascend a steep learning curve
to treat the variable wastewaters that a
single well is capable of producingrdquo
Tisdale notes that these inhibitors
while still acute are beginning to take on
a new form This is partially due to signifi-
cant gains in water management experi-
ence realized adoption of more efficientwater management strategies among
well operators and the emergence of
new policy mechanisms from regulators
that are playing catch-up with the fast-
moving hydraulic fracturing industry
trendlines
Treatment2
Disposal
6
Supply10
Storage22
Transport60
US $638Billion
S O U R C E B L U E F I E L D R
E S E A R C H
Write in 23 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
Industry-Leading
Warranties
Temperature Measurement Solutions
bull Probe type industrial RTDsbull Electronic temperature switchtransmitter bull Vapor-actuated remote thermometersbull Digital temperature indicatorsbull Platinum resistance temperature transmitterbull Compact OEM temperature transmitter bull Industrial amp instrument type bimetal thermometersbull Thermowells
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1445
New Technique Could ReduceEnergy Required for Oil Refinement
UK scientists have developed a
technique they say has the poten-
tial to dramatically reduce the amount
of energy required for the refinement
of crude oil
Professor Martin Schroumlder and Dr
Sihai Yang from The University of Not-
tingham (wwwnottinghamacuk ) have
led a multi-disciplinary team of scien-
tists from Nottingham the Science and
Technology Facilities Councilrsquos (STFC)
ISIS Neutron Facility Oak Ridge Na-tional Laboratory and Diamond Light
Source to discover a porous material
that works like a chemical sponge to
separate a number of important gases
from mixtures generated during crude
oil refinement
According to a news release from
The University of Nottingham the ex-
isting industrial process uses ldquohuge
amounts of energy to separate and pu-
rify these gases so the new technique
has the potential to revolutionize the oil
industry by significantly reducing car-
bon emissions and making the process
more environmentally friendlyrdquo
Commercially UsefulCrude oil is a raw material that is
refined to produce fuel for cars toheat homes and to create polymers
and other useful materials It is made
up of a complex mixture of hydro-
carbons (chemical compounds that
contain only hydrogen and carbon) of
which certain components are espe-
cially commercially useful
One industrial process used to
achieve hydrocarbon separation is
called ldquocryogenic distillationrdquo which is
widely used worldwide and uses vast
amounts of energy to generate the high
pressures and cryogenic temperatures
required to ensure efficient separation
research amp development
wwwflowcontrolnetworkcom January 2015 | 11
PLASTIC CONTROL VALVES FORALL YOUR CORROSIVE APPLICATIONS
PO Box 938 bull Angleton TX 77516Tel (979) 849-8266 bull wwwcollinsinstcom
Collins plastic control valves are
highly responsive control valves
designed for use with corrosive
media andor corrosive atmos-
pheres
Collins valves feature all-plastic
construction with bodies in PVDF
PP PVC and Halar in various body
styles from 12 - 2 with Globe
Angle or Corner configurations and
many trim sizes and materials
Valves may be furnished without
positioner for ON-OFF applications
Call for more information on our
plastic control valves
Write in 9 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1545
of hydrocarbon mixtures into pure components
However researchers say an innovative solution may
have come in the form of a novel chemical sponge This
porous material a metal-organic framework was devel-
oped by the same team at Nottingham just two years ago
Now in research published in Nature Chemistry for the
first time scientists have proven that it can be used toseparate hydrocarbon mixtures without the need for high
process pressures or very low process temperatures
Reusable MaterialsMade from cheap organic materials aluminum nitrate
salt and water the porous material called NOTT-300 is
able to adsorb different gases found in mixtures of hydro-
carbons at different rates making it possible to sepa-
rate them and extract the most useful ones NOTT-300
requires less energy to function than existing methods
as it operates at ambient temperatures and normal pres-
sures researchers say The gases that are adsorbed intoNOTT-300 can be removed without a significant energy
input and therefore the material can be easily reused
The team of scientists from Nottingham used Diamond
the UKrsquos synchrotron science facility as well as STFCrsquos
ISIS Neutron Facility and Oak Ridge National Laboratory
the UKrsquos and USArsquos world-leading neutron facilities re-
spectively to prove that the sponge works under real-life
conditions
Professor Martin Schroumlder Dean of the Faculty of Sci-
ence at Nottingham said in the news release ldquoIt is a very
important to be able to separate different hydrocarbons ef-
fectively and efficiently with low-energy consumption Po-rous solids such as the metal-organic framework system
studied here represent important materials for the future
development of low-energy separation technologies We
are most grateful to our collaborators at ISIS Neutron Fa-
cility Oak Ridge National Laboratory and Diamond Light
Source in bringing this work to fruitionrdquo
Significant Impact on Oil IndustryDr Sihai Yang the winner of Diamond Young Scientist
and BTM Willis Prize is a Senior Research Fellow at
Nottingham He led the project together with Professor
Martin Schroumlder Yang said ldquoWith the help of advancedcentral facilities like Diamond ISIS and ORNL we have
developed a new separation technique which can poten-
tially reduce the energy usage associated with oil petro-
leum and chemical industries which require the separa-
tion of raw hydrocarbons from crude oil
The discovery of the new material NOTT-300 could
have a significant impact on the oil industry by removing
the necessity for some energy-intensive refinement pro-
cesses researchers say
The research was funded by Engineering and Physical
Sciences Research Council (EPSRC) the European Re-
search Council (ERC) The University of Nottingham andLeverhulme Trust
12 | January 2015
Flow Control Magazine
Write in 21 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
No media contact - No risk of leaks
No process Shut-Downs for installation
No bypass needed
For hazardous area locations (FM approved)
Monitor your Total Acid Consumption
Increase your Plant Up-Time
Balance your Processes
PIOXreg S
PIOXreg S - the evolution of flow and concen-
tration measurement in acid production
Non-intrusive mass flow concen-
tration and density measurement
of aggressive media
wwwpiox-scom
wwwfleximcom
Contact us for a free trial measurement
Thank you for your votes and
making PIOXreg S a Flow Control
Awards Winner
THE OUTLOOK | News amp Notes
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1645
The ASCO trademark is registered in the US and other countries The Emerson logo is a trademark and service mark of Emerson Electric Co copy 2014 ASCO Valve Inc
1-800-972-ASCO (2726) | e-mail info-valveascocom | wwwascovalvecomSpoolValve
Now get spool valves with industry-leading ASCO solenoid technology built in
Delivering unmatched performance and durability our compact new valves are
perfect fits for all your onshore near-shore or offshore upstream control panels A
range of easily configured features and options includes superior temperature and
pressure ratings plus low-power models The industryrsquos toughest testing ensures
every rugged stainless steel valve meets or exceeds specifications Plus we design
and support every spool valve we make Ask for ASCO the ultra-reliable choice for oil
and gas control panels
These new spool valves will fit right in
Write in 22 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 174514 | January 2015 Flow Control Magazine
PPLICATIONS CORNER | Process Instrumentation
This is the final article in a series based on the troubleshoot-
ing of a mysterious unit shutdown due to flowmeter perfor-
mance problems
If yoursquove followed this column for most of 2014 you know
that what should have been a liquid ammonia stream to the
feed plant became problematic due to the occurrence of
bubbles of ammonia gas These bubbles caused an ultrasonic
flowmeter in a unit to indicate zero flow and caused the reactor
to scram (shut down) under warm operating conditions The source of the bubbles was traced back to the pres-
sure drop associated with a control valve located at the
exit of the liquid ammonia tank farm
This issue was resolved by identifying the problem
and fixing it at its source This was a pragmatic ap-
proach at the time (early 1980s) given the operation
of the cooling system in the unit and the limited selec-
tion of applicable flowmeter technologies
By the early 1990s changes were implemented that elim-
inated all process cooling requirementsmdashexcept for the small
jacketed cooler upstream of the liquid ammonia flowmeter In
other words after these changes the entire cooling system
would be operated and maintained to cool a few meters of
one small ammonia pipe Coincidently at about the same
time Coriolis mass flowmeters became more mature and
could reasonably measure the mass flow of liquid streams
with homogeneous low levels of vapor
The convergence of these two events resulted in another
approach to the problem that was not available in the early
1980smdashie install a Coriolis flowmeter that could operate in
the presence of bubbles The purchase and installation of a
Coriolis mass flowmeter was given high priority given its im-pact on unit operation economics and safety (by eliminating
the ldquomidget-makerrdquo (see March 2014 page 14))
Plant requirements and the technology that can meet
plant needs keep changing An excellent solution today can
become outdated in just a few years However there are few
substitutes for understanding fundamentals when addressing
a problem In other words there can be more than one way
to skin a cat FC
wwwspitzerandboyescom
Problem Solved AgainA Coriolis mass flowmeter provides a better solution
F o r B e t t e r P i p i ng S y s t e m P e r f o r m a nc e hellipFor Better Piping System Performancehellip
I d e a l f o r Ag g r e s s i v e C h e m i c a l s
1384 POMPTON AVENUE CEDAR GROVE NEW JERSEY 07009
973-256-3000 bull Fax 973-256-4745www p l as t om a t ic co m bull i n f o p la s t om a t ic co m
bull Rugged thermoplasticshandle corrosive andultra-pure chemicaltreatments
bull Constant pressure enhances
pump performancebull Prevents overpressure in
piping system
bull Wide range of pressuresettings
bull PTFE shaft and diaphragm designs
bull 1 4rdquo - 3rdquo sizes in PVC CPVC PVDFPolypro and PTFE
bull First State approved
thermoplastic valve for
anti-siphon applications
Write in 10 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
David W Spitzer
Ammonia Gas | Coriolis Flowmeter | David W Spitzer | Scram | Troubleshooting
FLOWSTREAM Find related content flowcontrolnetworkcom
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and Boyes
LLC offering engineering seminars strategic marketingconsulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer can be reached at 845 623-
1830 or at wwwspitzerandboyescom
The purchase and installation of a
Coriolis mass flowmeter was given
high priority given its impact on unit
operation economics and safetyldquordquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1845
Smart Valve Positioner
Beyond Control The NEW Research Controlreg SRD positioner does
everything you expect any valve positioner to do
plus more The SRDrsquos comprehensive diagnostics tool
continuously monitors for fugitive emissions delivers
real-time performance statistics and facilitates both
proactive and reactive process management Available
with integrated network communications the SRD is
compatible with Research Control valves and most other
pneumatically-actuated valves
Visit wwwbadgermetercomSmart-Valve-Positioners or
call 877-243-1010 for more information today
copy 2015 Badger Meter Inc
RESEARCH CONTROL is a registered trademark of Badger Meter Inc
Write in 11 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1945
Process improvements to increase yield or cut manufactur-
ing costs typically require enhanced process control but the
installed base of measurement instrumentation in a process
plant may simply be unable to facilitate improvements because
of age inadequate performance or unreliability Maintenance
cost and unscheduled process downtime for an aging process
plant can be very damaging to the balance sheet Upgrading
to new more accurate and more reliable instrumentation can
be prohibitively expensive New plant construction must alsomaintain a focus on optimizing costs for the process control
infrastructure The budget approval decision for new plant
construction must weigh such costs against projected market
conditions for the products that the plant is intended to manu-facture In todayrsquos volatile global marketplace return on invest-
ment calculations for plant upgrade or new plant construction
projects may go through several iterations before the trigger is
finally pulled or indeed not pulled
This article describes advances in two-wire instrumenta-
tion specifically in relation to flowmeters that have taken
place in the past few years and the significant cost benefits
that this new technology can realize for plant builders and op-
erators in terms of capital investment and cost of ownership
The Significance of Two-Wire Loop Power
A survey involving 204 participants in the chemical indus-try across Germany Switzerland the UK Canada and the
United States (Manfred Koenig PhD KIM Ludwigshafen
Germany 2006) revealed an 87 percent preference for two-
wire instrumentation versus four-wire in process applications
and 89 percent for utilities This overwhelming preference
may stem from the fact that older process plants were built
with two-wire twisted-pair cable networks connecting all
process units and measuring instruments together in an
overall plant control scheme
However these existing cables are relatively unsophisti-
cated and incapable of supporting anything but low-energy
instrumentation that is insensitive to interference from otherelectrical sources that might be sharing the same cable con-
duit Further the low energy levels supported by these two-
wire loops are more easily rendered safe in terms of explo-
sive risk in hazardous areas containing flammable materials
Many older process plants are also likely to have a significant
installed base of flowmeters employing pre-war (pre-1945)
technology such as positive displacement (PD) turbine vari-
able area (VA or Rotameter) and differential pressure (dP)
Market data firm Flow Research Inc (wwwflowresearch
com) indicates collectively a future compound negative annual
growth rate approaching minus 3 percent to 5 percent for PD
turbine and VA flowmeter types while dP is expected to keeppace with market growth (World Market for Flowmeters 2010)
YSTEMS DESIGN | Flow Measurement
16 | January 2015
Flow Control Magazine
The Two-Wire
ADVANTAGENew wiring options enable modern instrumentsto drive cost savings in existing plant systems
By Steve Milford
Advances in two-wire instrumentation have enabled mod- ern technology to be employed to the advantage of older
plant and process systems
Some chemical manufacturing plants are
competing for survival not only externally
against other global companies but also
internally among the global facilities of theirown company Other industry sectors face
similar challenges
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2045wwwflowcontrolnetworkcom January 2015 | 17
The Need to Replace Older TechnologiesUntil the 21st century two-wire loops were only able
to support these relatively unsophisticated instruments
which convert their measurement by various means into a
4-20mA output or pulse signal to the control system The
more advanced post-war flowmeter technologies such as
Coriolis ultrasonic or electromagnetic flowmeters have
until just eight years ago required a dedicated power sup-
ply for their function in addition to the output loop and
thus a four-wire infrastructure was required as a minimum
Therefore upgrading older two-wire meter devices to moremodern four-wire technology could require significant
expenditure in terms of the installation of separate power
cables and supply modules
There was a major breakthrough in 2006 when a true
two-wire loop-powered inline liquid ultrasonic flowmeter
was introduced (Figure 1) The nature of this breakthrough
was innovation in device power management This was the
missing piece up to that point because to be a true loop-
powered device the meter had to directly provide a full 16
mA span using less than 36 mA of remaining loop current
and less than 1 Watt of electrical energy The flowmeter
operated on a single 4-20 mA HART two-wire loop wasremotely powered by a DC supply was certified Class 1 Divi-
sion 1 and could be deployed as Intrinsically Safe through
the use of an approved safety barrier
A true two-wire loop-powered Coriolis flowmeter followed
in 2011 (Figure 2) employing a new and more advanced
common electronics platform A two-wire loop-powered inline
ultrasonic flowmeter for low-pressure gas was introduced in
2012 and a second two-wire loop-powered Coriolis meter fol-
lowed in 2013 offering improved measurement performance
and an additional high-performance meter tube material
Electromagnetic and vortex flowmeters had already been
available for some years in two-wire loop-powered form butimproved performance resulted as these designs were incor-
COURTESYENDRESS+HAUSER
Figure 1 A two-wire ultrasonic flow- meter released in 2006 operated ona single 4-20 mA two-wire loop
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 214518 | January 2015
Flow Control Magazine
porated into their new common electron-
ics platform in 2013 So all the ldquomodernrdquo
flow measurement technologies mdash that
is to say those introduced post-war mdash
have become available as two-wire loop-
powered devices with one exception
namely thermal mass (thermal disper-
sion) meters Unfortunately the power
requirements for this technology exceed
what is currently deemed possible withtwo-wire loop-power management
Payback forTechnology UpgradeConsider a 1rdquo process line
containing a liquid process
ingredient costing $1lb at a
mass flowrate of 150 lbmin-
ute We have $150minute
flowing in the line translating
to $9000hour and $72000
per eight-hour shift That cal-culates further to $360000
per five-day working week and
for a working year of 40 weeks for
example that is $144 million Assume
the existing device is a turbine flowmeter
Now imagine a two-wire loop-
powered Coriolis mass flowmeter is
installed in place of the existing meter
The line would need to be drained and
probably one process flange replaced
allowing the Coriolis to fit mechanically
in place of the turbine However thetwo-wire loop already used for carrying
the existing meterrsquos flow signal to the
control room can be used unaltered
for the complete electrical installation
aspects of the Coriolis flowmeter
The upside of the change is signifi-
cant and clear cut Assuming the exist-
ing meter measurement uncertainty was02 percent of reading then measure-
ment uncertainty improves through use
of Coriolis to 01 percent of reading
giving a 01100 x $14400000 im-
provement in control of the ingredient
annually or $14400 A two-wire Coriolis
mass flowmeter with 01 percent mass
flow accuracy would be paid for in ap-
proximately 6-8 months In practice the
improvement in measurement uncer-
tainty would be greater as the operator
would gain temperature and density in-formation from the Coriolis and the mea-
surement would be devoid of any fluid
property dependence Viscosity change
for example can have a major impact on
turbine meter performance Mechanical
wear and tear that turbine meters even-
tually experience which causes them to
under-register flow is precluded by mod-
ern devices like Coriolis
Furthermore if the process ingredient
was being blended with another then ad-
ditional process improvements could berealized through in-line blending control
using Coriolis technology for final density
as the control point It is possible to have
dual 4-20 mA outputs from two-wire
loop-powered meters but as the main
4-20 mA output representing the prima-
ry variable is also HART then an external
HART Loop Converter or HART IO card in
the control system can provide second-
ary tertiary and quaternary variables as
4-20 mA signals A Coriolis meter is trulya multi-variable device Certain two-wire
devices are also available with Profibus
or Foundation Fieldbus communication
Cutting Wiring CostsIn 2003 WIBEXERA (International
Instrument Usersrsquo Associations) Report
T 2732 X 03 was published and it pro- vided an average survey of prices quoted
in projects at that time for the provision
of power supplies for four-wire instru-
ments The price ranged from euro1200
to euro1800 per instrument depending
upon design and plant characteristics
for an average cost of euro1500 (about
$2000) It would be reasonable to
assume an inflationary factor of 2 per-
cent per annum giving an approximate
current-day figure of $2500
From another source within thechemical industry an estimation of
$40foot to $50foot was given for in-
stallation of four-wire cabling For a
linear 50-foot cable run with for ex-
ample a 10-foot vertical at each end
this equates to $3150 Actual costs
and budget estimates have been given
as high as $10000
The Extent of the Opportunity The modern post-war flow measure-
ment technologies have different powerrequirements and consequently they
are not all available for the
same size range in two-wire
loop-power form For example
two-wire Coriolis flowmeters
are limited to 2rdquo diameter
electromagnetic and inline
low-pressure gas ultrasonics
are limited to 8rdquo and vortex
and inline liquid ultrasonic are
limited to 12rdquo
Nevertheless for thechemical industry in particu-
lar perhaps two-thirds of the
process pipes in a plant will be no larger
than 2rdquo and even when the host process
pipe is larger a correctly sized flowmeter
can still be less than 2rdquo There is consid-
erable scope for two-wire loop-power to
deliver value for flow measurement ap-
plications with total safety
The virtues of Coriolis technology
have been covered but what about
other two-wire technologies An elec-tromagnetic flowmeter in two-wire form
YSTEMS DESIGN | Flow Measurement
In todayrsquos volatile global mar-
ketplace return on investment
calculations for plant upgrade or
new plant construction projects
may go through several itera-
tions before the trigger is finally
pulled or indeed not pulled
ldquo
rdquo
COURTESYENDRESS+HAUSER
Figure 2 Two-wire Coriolis flowme- ters became available in 2011
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2245
can be used on water wastewater or
a light water-based slurry provided the
fluid has around a 20 microSeimenscenti-
metre (microScm) electrical conductivity
A magnetic flowmeter is full bore un-
less flowrates dictate a reduced meter
size in the interests of performance and
so there are no intrusions into the flow
stream and no pressure loss An accu-
racy of 05 percent of reading is normal
from a two-wire magnetic meter and a
modest five diameters (5D) of straight in-let run is needed to avoid error from up-
stream flow disturbances When the fluid
exhibits insufficient conductivity then
the same performance and installation
requirements can be met by an inline ul-
trasonic flowmeter provided the liquid is
essentially clean and bubble-free
For gas or steam applications a vor-
tex meter is the normal choice Using a
built-in temperature sensor a two-wire
loop-powered vortex meter can calculate
mass flow of saturated steam using in-ternal steam tables An external pressure
input allows mass flow of steam to be ac-
curately calculated even when saturated
steam becomes superheated as can oc-
cur downstream of a pressure regulating
valve With mass flow known the vortex
meter can calculate energy and heat flow
A new and exciting development is
the ability of the vortex meter to indicate
wet steam and calculate dryness frac-
tion or steam quality For safety and ef-
ficiency saturated steam should be dry
and free from condensate that is to say
it should possess a high steam quality
factor However the dry or wet state of
saturated steam can sit on a knife-edge
and shift to the opposing state due to
the slightest change in process condi-
tions Rapid and reliable indication of
this change of state is now available
Perhaps the most astonishingachievement in the power management
of two-wire loop-power flowmeters is
that of the ultrasonic biogas meter It is
now possible not only to measure the
flow of wet dirty variable composition
and low-pressure anaerobic digester
gas landfill gas and coal bed methane
gas with a two-wire loop-powered ultra-
sonic flowmeter but also the same de-
vice uses an inbuilt temperature sensor
in combination with measured sound
velocity to calculate methane contentcalorific value and energy flow
Technology to Take UsForwardModern flow technologies provide instru-
ment engineers with vital self-monitoring
information The format of such infor-
mation is easier to understand and act
upon when presented in accordance
with harmonized international guidelines
for online plant asset management eg
NAMUR Standard 107
Continuous plain-text self-diagnostic
and process-related information with
suggested remedies (Figure 3) make it
possible for instrument engineers andoperators to take action at the appro-
priate time mdash immediately or during
the next scheduled shutdown mdash saving
time and money by knowing the exact
health of their measuring point and the
probable actions required to rectify any
abnormal conditions Device verifica-
tion offering third-party validated trace-
ability can be performed on demand ei-
ther locally or remotely from the control
room without the expense of a man in
the field Calibration is then avoided ordeferred without process interruption
Where a process plant has a large
installed base of older mechanical tech-
nologies the decision to embark upon a
program of replacement for plant mod-
ernization cannot of course be taken
easily There are the stocks of spare
parts to consider along with the plant
instrument technicians who are trained
on and at ease with the old devices
However a process plant that retains
the older technology going forward willbe at risk and may find it increasingly
difficult or even impossible to maintain
a cost position that competes effective-
ly in the global market FC
wwwusendresscom
wwwflowcontrolnetworkcom January 2015 | 19
Steve Milford
is a Flow Product
Business Manager
for Endress+Hauser
Inc in Greenwood
Ind He has been
involved in flow
measurement since
1983 and has been
actively involved with standards devel-
opment for flow technology within the
International Standards Organization
(ISO) and the British Standards
Institute Mr Milford can be reached
at stevemilfordusendresscom
Steve Milford
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Coriolis Flowmeter | Magnetic Flowmeter | Two-Wire | Ultrasonic Flowmeter | Vortex Flowmeter
Figure 3 A modern instrumentrsquos display module can provide continuous plain- text self-diagnostic and process-related information
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2345
The bottom line is the volume of gas under one set of
pressure and temperature conditions is not the same as it
would be for the gas under different conditions Why is thisimportant Without compensation for compressibility read-
ings taken by gas flowmeters can result in measurementsmdash
and costs to the buyermdashsignificantly lower or higher than they
should be
The flow of gas in a system can be accounted for and
reported in a number of ways such as by volume by mass
flowrate and by energy Inline turbine meters can offer both
reliability and accuracy in measuring gas flow when matched
with a monitor capable of calculating and displaying results
that have been adjusted for the nature of the gas and impor-
tantly the pressure and temperature
Measuring Flow with an Inline TurbineFlowmeter
With an inline turbine meter gas flows into the meter through
a length of piping that helps to pre-condition the flow by
reducing undesirable swirls and asymmetry Where consid-
ered necessary a flow straightener may even be installed in
line to create a uniform flow profile to the extent possible
As can be seen in Figure 1 a rotor support within the tur-
bine housing further conditions the flow and directs it through
the blades of the rotor High-precision ball bearings allow the
rotor to freely rotate on the shaft
The rotorrsquos rotational speed is directly proportional to the velocity of the fluid passing through the meter The rotor itself
incorporates magnets (or magnetic blades depending on thedesign) while the housing is non-magnetic
A proximity sensor (also known as a pickup coil) is located
in line with the rotor and detects the electrical pulses gener-
ated by the ferrous rotor spinning through the magnetic field
Each pulse represents a discrete volume of gas The out-
put frequency provides the indication of the gas flow rate and
the accumulated pulses over a specified time represent the
total volume of fluid for that measurement period
Need for Calibration The flowrate of the gas through the meter cannot be deter-
mined accurately unless the meter is calibrated The fac-tory calibration determines the meterrsquos constant known
as a K-factor which is then inputted into the gas monitor
PPLICATION NOTES | Flow Measurement
20 | January 2015
Flow Control Magazine
COMPENSATING for
Compressibility inMeasuring Gas Flow Why K-factor adjustment is essential foraccurate inline turbine flow measurement
Unlike crude oil and other liquid fossilfuels natural gas poses a challenge
in monitoring the quantity of gas flowing
through pipelines While liquids do not com-
press gases do and the mass flowrate of
gas being transmitted through gathering
lines depends on both the pressure and
temperature
By Kevin Clark
Figure 1 Internal components of a liquid turbine flowmeter
C O U R T E S Y
T U R B I N E S
I N C
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2445
Wondering Whether the
Pump Guy Seminar
Is for YouCheck out the ldquoPump Guy Insightsrdquo
video series flwctrlcompginsights
PUMP GUY INSIGHT 1NPSHa vs NPSHrmdashWhy all pumps need gauges
PUMP GUY INSIGHT 3How to Operate Your Pump at Best Efficiency
PUMP GUY INSIGHT 5Head vs Flow
PUMP GUY INSIGHT 2 Your Pumps Are Constantly Moving On Their Curves
PUMP GUY INSIGHT 4 The Role of the Pump Reliability Chain
PUMP GUY INSIGHT 6How to Read a Pump Curve
PARTNER SPONSORSFor more information and to register
for upcoming Pump Guy Seminars
visit FlowControlNetworkcomPumpGuy
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2545
PPLICATION NOTES | Flow Measurement
22 | January 2015
Flow Control Magazine
Gas flowmeters measure the actual volume of gas passing
through the meter per minute irrespective of pressure and
temperature1
The volumetric flowrate of a gas is often corrected to
ldquostandardizedrdquo conditions of pressure and temperature While
ldquostandardrdquo conditions can vary depending on the definition
in the US this typically means a pressure of 1473 PSIA(pounds per square inch absolute) and a temperature of 60 F
The flowrate measurement is reported in standard cubic feet
per minute (SCFM)
Compensating for changes in pressure and temperature is
critical Consider a meter system setup for flowing conditions
of 60 PSIG (pounds per square inch gauge) and 60 F and the
line pressure decreases to 50 PSIG while the temperature
remains constant The difference in SCFM between the two
is more than 15 percent which would cost the buyer more
for the gas than it should As Table 1 demonstrates even a
small variation in pressure will result in a surprisingly high er-
ror percentage
Automation of the K-Factor The K-factor is established by an initial factory calibration In
the case of a non-compensated flow monitor any variations
in pressure and temperature will result in manual adjust-
ments needed to the K-factor In order to maintain accurate
flow measurement users must monitor pressure and temper-
ature and make corresponding adjustments to the K-factor To eliminate these manual adjustments some suppliers offer
a flow monitor that automatically adjusts for any changes in
pressure and temperature
These monitors provide accurate flow measurement regard-
less of changing environmental conditions in some cases sup-
porting applications with pressures as high as 15000 PSIG and
temperatures between -350 F to 350 F with a standard accura-
cy of +-1 percent over a flow range of 05 ACFM to 650 ACFM
Final NotesDuring the operation of a flowmeter system the ability to obtain
a readout mdash and to adjust for line pressure and temperaturechanges mdash is sometimes compromised by a lack of electric
power This issue is especially true along gas pipelines in remote
areas To overcome this limitation some manufacturers have
designed low-powered flow monitors which can operate for up
to on year on a single lithium D-cell battery
It is important for users to recognize the effects of the
compressibility of gas As such the quantity of a gas flow-
ing through a gas flowmeter depends on the pressure and
temperature In order to ensure accuracy any flowmetering
system must employ a means to correct for these effects
Otherwise the readout is certain to be in error and could be
unnecessarily costing money This is particularly crucial onwellhead production and in billing scenarios FC
wwwturbinesincorporatedcom
Notations1 The measurement factor in the US is known as the
ACFM actual cubic feet per minute (Metric units are typically
ACMH actual cubic meters per hour)
Table 1 Error induced by line pressure changes
Constant Temperature with Varying Pressure
Pressure Temperature PulsesSCF Error
50 60 2556027821 1546
51 60 2517123288 1370
52 60 2479385307 1199
53 60 2442762186 1034
54 60 240720524 873
55 60 237266858 717
56 60 2339108911 566
57 60 2306485356 418
58 60 2274759285 275
59 60 2243894166 136
60 60 2213855422 000
61 60 2184610304 132
62 60 2156127771 261
63 60 2128378378 386
64 60 210133418 508
65 60 2074968632 627
66 60 2049256506 743
67 60 2024173807 857
68 60 1999697703 967
69 60 1975806452 1075
70 60 1952479339 1181 Flow Measurement | K-Factor | Measurement
Accuracy | Turbine Flowmeter
Find related content flowcontrolnetworkcomhellipSearch on
FLOWSTREAM
Kevin Clark is senior develop-
ment engineer for Turbines Research
amp Development LLC Turbine RampD is a
subsidiary and the research and techni-
cal support arm of Turbines Inc which
serves a range of industries and applica-
tions from oil amp gas to cryogenic liquids
to custody transferKevin Clark
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2645
Pumps Bearings amp Seals TECHNOLOGY REPORT
FEATURES
SYSTEMS DESIGN
The ComplicatedCase of
Compressors
withSide-Streams
24 28 32BEST PRACTICES
How PumpingSystems
AffectSealing
Performance
TECH OUTLOOK
BearingSuppliers
Drive Gains InDeveloping
Markets
wwwflowcontrolnetworkcom January 2015 | 23
S P E C I AL S E C T I O N
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2745
The design and operation of compressors with side-
streams has always been difficult because flow entering the
compressor needs to be mixed with the core flow already
in the compressor (compressed in section-1) in a manner
that does not degrade the aerodynamic performance of sur-
rounding sections Minimizing losses and ensuring proper
mixing of the side-stream flow and core-flow are required to
ensure effective performance of a compressor of this sort
Key considerations for an application involving compres-
sors with side-stream flow include
The plant process typically dictates the side-stream
flange pressure
The impellers upstream of the side-stream should
achieve the necessary pressure for the core-flow
The side-stream flow is typically at a temperature dif-
ferent from compressor core-flow temperature
Process plants need some degree of operational flex-
ibility ie the ability to support variations in core-flow condi-
tions and side-stream conditions
Modern process plants are usually specifying more than
one operating conditions (sometimes two or more manda-
tory conditions) which can present challenges to compres-
sors with side-streams Adding to these issues modern
compressors should operate with much higher impeller tip
The COMPLICATED CASE ofCompressors with Side-StreamsConsidering key system design requirements
to ensure operational efficiency By Amin Almasi
4 January 2015
Flow Control Magazine
|
y
g
Some compressors in certain applications
have one or more incoming side-streams
(or side-loads) that introduce side-stream
flow to mix with the core flow In other words
a radial side-stream inlet is utilized in multi-
impeller centrifugal compressors to introduce
additional gas into the mid-stage of a com-
pressor This design enables optimization in
some process plants However the flow dis-
tribution after the junction of the side-stream
and the main return channel of the upstream
section can significantly affect the perfor-mance of the next section of compressor
In most cases the pressure levels at these
side-streams should be accurately predicted
to meet the theoretical performance
Compressor station at a natural gas processing plant
R U D M E R Z W E R V E R I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2845
speeds and inlet Mach numbers compared to previous
generations of compressor technology
Likewise side-streams are now com-
monly used with medium-sized and
large-sized compressors (eg 1ndash60
MW) The costs associated with cor-
rections on side-stream compres-
sor applicationsmdashany repair
inefficient operation and power
lossesmdashwould be very high Fur-
ther compressors with side-streams
are usually sensitive and difficult
machines to operate In particular
performance curves (performance
pressures efficiency etc) are sen-
sitive to suction inlet conditionsside-stream inlet conditions vol-
ume flow ratio (side-stream vol-
ume to core-flow volume) and side-stream losses
Compressors with side-stream often perform far below
expectations The main reason is that side-stream compres-
sors are different than conventional compressors (without
a side-stream) in design and operation For a compressor
with side-streams tighter tolerances in operating conditions
must be identified and applied Uncontrolled variations of
suction pressure or side-stream pressure are major prob-
lems Another major issue is the variations of the flow ratio
(side-stream flow to core-flow)
Compressor Side-Stream amp Mixing SectionIn many centrifugal compressors the portion of the side-
stream system from the flange connection to the mixing
section is similar to a compressor inlet A great challenge
is ensuring the mixing section provides circumferentially
uniform merged-flow with minimum losses This can be
achieved via effective design of the inlet configuration and
mixing section of the side-stream compressor such that
the impeller can be maintained over the whole operating
range of the compressor In many cases while there are
mixing sections provided for the machine the flows do not
completely mix before entering the impeller of the section-2
(the impeller after the mixing section) Non-uniformity at
inlet flow to the impeller is a key concern for compressor
performance
Another consideration is a compact design of the side-
stream mixing section Specifically a mixing section with
less axial length is always preferred This axial length can af-
fect the compressor rotor dynam-
ics the rotor length and over-
all compressor performance
(design cost operation and
reliability)
The side-stream exit pressure
(side-stream pressure at inlet
of the mixing section) is mainly
a function of the side-stream
flow velocity and the pres-
sure in the previous section of
the compressor Conversely the side-
stream flange pressure can depend on
side-stream flow velocity and section-1
exit conditions Therefore the side-stream
inlet flange volume flow is a function of theflange pressure compressibility (at that
pressure and temperature) and mass flow
Some engineers assume that the side-stream flange pres-
sure is equal to the inlet pressure of the first impeller of the
section-2 This is not true The mixed total pressure can be
estimated on a mass-averaged basis using side-stream total
pressure and return channel exit (section-1) total pressure
In some designs because of the lower static pressure at
the side-stream exit the total pressure at the return channel
exit is lower even though the velocity upstream is roughly
matched for both streams The pressure usually increased
at the returned channel but it can be reduced again at the
side-stream exit While simple in nature this can have an
impact on the prediction of pressure at the side-stream exit
and overall mixing section performance Based on basic flow
principles it was usually assumed that the static pressure
was equal between both flow streams at the mixing location
While this assumption might be used in rough calculations
the accurate simulations have shown this assumption is not
true In fact there are some points (for instance the shroud
wall at the exit of the return channel and the hub wall at
the exit of the side-stream) where this assumption is true
However this is not valid for all locations There are pressure
changes that occur from a side-stream flange to the inlet
of the next section (section-2) which depend on different
factors The first factor is the frictional losses due to side-
stream geometry from side-stream flange to plenum mix-
ing section etc The other factors are pressure changes due
to local curvature and geometry details of mixing section
Another consideration is the operation of a compressor
with side-stream at part-load The performance of the side-
wwwflowcontrolnetworkcom January 2015 25
Figure 1 An example of a centrifugalcompressor with side-stream
COURTESY SIEMENS
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 29456 January 2015
Flow Control Magazine
|
y
g
stream path the mixing section and
the downstream impellers when ma-
chine is operated at part-load or even
off-design operating flows will result
in additional compressor performance
problems In such a case both veloc-
ity profiles and pressure variations in
various parts (side-stream path mixing
section etc) will be different resulting
in complicated flow patterns and com-
plex aerodynamics behaviors
Side-Stream CompressorSectional Performance
Typically vendor-supplied compressor
performance curves reflect flange-to-flange performance because that is
what the plant engineers need to
evaluate the proper operation of their
system (for example from suction to
side-stream and from side-stream to
discharge) In many cases compres-
sor vendors also provide the over-
all compressor performance curves
and performance curves for section-1
(from suction to side-stream) and sec-
tion-2 (from side-stream to discharge)
Flange-to-flange data if not interpret-
ed properly can lead to false conclu-
sions about the relative performance
of individual sections of a compression
system For example if side-stream
losses from the flange to mixing sec-
tion are attributed to the downstream
section (section-2) it will cause the
downstream section (section-2) to
appear low in performance while the
upstream section (section-1) will show
high performance levels
An important behavior to con-
sider is when the actual side-stream
pressure is different than the rated
side-stream pressure When the side-
stream pressure is slightly higher than
the outlet pressure of the section-1
it (section-1) shows a relatively higher
performance compared to the real sec-
tion-1 performance In some cases
the performance of section-1 could be
considerably higher than section-2 In
other words when performance is de-
termined flange to flange the higher
flange pressure is seen as extra ldquopseu-
dordquo work done by the section (since this
is an inconsistent thermodynamic vol-
ume) resulting in a relatively high sec-
tional efficiency (section-1 shows a rel-
atively high efficiency) This is the case
for many compressors with side-stream
because the whole system is designed
(or specifically the side-stream location
is selected) in a way aimed at main-
taining the real side-stream pressure(side-stream inlet) above the section-1
outlet pressure because if the real side-
stream pressure becomes lower than
the section-1 outlet pressure the flow
may (theoretically) reverse
This is particularly important when
the side-stream mass flow is much
lower than the mass flow of core-flow
The above-mentioned reasons explain
why in many simulations calcula-
tions and performance reports related
to compressors with side-stream the
section-1 shows a relatively good ef-
ficiency and section-2 appears low in
efficiency
When the side-stream pressure is
slightly lower than the outlet pressure
of the section-1 the section-1 might
show a relatively lower performance
compared to section-2 This could oc-
cur in some recycle services where the
side-stream is actually a recycle flow
with a mass flow around two to five
times the core-flow The side-stream
(recycle) flow is returned from down-
stream of the compressor to be slightly
compressed and recycled to the down-
stream Such a recycled side-stream
compressor can present unique chal-
lenges for design and operation This
kind of machine usually needs very
special operating procedures and very
fine adjustments regarding operating
pressures and flows
Side-Stream Compressor
Performance amp Operation An important consideration is the sen-
sitivity of compressor overall perfor-
mance curve and sectional perfor-
mance curves to the flow ratio (ratio
of side-stream flow to core-flow) and
to the inlet conditions Variations in
the flow and pressure of the main
suction and side-stream inlet should
be controlled within tight tolerances
For compressors with side-stream the ASME PTC-10 code stipulates limits on
flow ratio (side-stream volume to core-
flow volume) The acceptable variation
in volume flow ratio in a compressor
with a side-stream is +-5 percent as
per ASME PTC code The requested
side-stream pressure tolerance is not
usually specified in compressor codes
but it should be around +- 2 percent
(or sometimes +- 25 percent)
Variance in flow ratio impacts the
velocity levels where the two streams
merge Significant variation in the ve-
locity profile upstream of the impeller
changes the incidence on the blade
leading edge of the following impel-
ler This change in incidence leads to a
change in sectional performance over-
all compressor performance and train
efficiency
If the flow ratio is varied between 95
percent and 105 percent (tolerances
specified in the ASME PTC-10 code)
the flange pressure changes accord-
ingly resulting in a change in the sec-
tional performance and overall perfor-
mance The sectional efficiency varies
sometimes more than +- 4 percent
This variance reduces as the flow is de-
creased toward surge However as the
flow is increased toward overload the
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3045wwwflowcontrolnetworkcom January 2015 27
variance increases up to higher values
(even in some cases three to five times
compared to variations near the surge
zone) For example in a case study
for a compressor with side-streams a
+- 5 percent variation in flow ratio and
associated changes (pressures losses
etc) the sectional efficiency reduced by
approximately 34 percent at the rated
flow at allowable operating points at
the end of curve (near the overload
ie choke) efficiency reduced by ap-
proximately 55 percent These results
show that the variation in sectional
performance and overall performance
due to flow ratio is highest at operat-ing points near the overload and low-
est at operating points near the surge
For compressors which work most of
the time at high flow (flow higher than
rated flow and discharge pressure low-
er than rated pressure) the effects of
flow ratio deviations (and subsequently
efficiency reduction) would be higher
than compressors working on the left-
hand side of curve (say with sufficient
margins near the surge)
In the compressor codes (such as
API 617) the compressor power varia-
tions should be maintained below 4
percent However in some applica-
tions clients require tighter tolerances
on the consumed power sometimes
below 2 percent (or even below 15
percent) Some studies suggest while
+- 5 percent of volume flow ratio is
suitable for performance test as per
ASME PTC-10 code some plants re-
quire tighter control on the consumed
power and compressor performance
(lower limits on the efficiency) the tol-
erances on the volume flow ratio could
be tighter than ASME PTC code In this
regard +- 4 percent tolerance can be
suggested on the volume flow ratio (ra-
tio of side-stream flow to core-flow) of
compressors with side-streams
Based on operational experiences
acceptable variations in volume flow
ratio and inlet pressures (suction inlet
and side-stream inlet) of a compressor
with side-streams are +- 4 percent
and +- 2 percent respectively
Another important consideration is
the required adjustments for the flow
ratio (side-stream flow to core-flow)
Compressors with side-stream usually
require fixed side-stream flange pres-
sures For a compressor with some variations in operation conditions (even
small changes) it is not usually pos-
sible to achieve optimum operation by
keeping the flow ratio (side-stream to
core-flow) constant The flow ratio has
to be adjusted according to the inlet
flow at which the machine is operating
in order to get the required correspond-
ing side-stream flange pressure
Thermal changes have also been
known to cause some instability in
centrifugal compressors An example is
the thermal-induced change of resid-
ual unbalance For compressors with
side-streams which feature tempera-
ture differences between core-flow and
side-stream flow the thermal behav-
ior of the compressor is usually more
complex and requires more attention
Heavy Gas ChallengeHeavy gases (such as heavy hydrocar-
bon gases eg propane propylene
MTBE (Methyl Tertiary Butyl Ether))
have very low gas sonic velocities that
produce high Mach numbers in the
aerodynamic flow paths For these
services because of high Mach num-
ber high flow coefficient stages have
very narrow flow maps characterized
by limited surge and choke margins
Compressors with side-streams in
these services present great challeng-
es This is to say the side-streams and
associated mixing further complicate
design operation and performance
prediction because the pressure tem-
perature and flow conditions at each
one of these side-streams as well
as at the exit of the machine require
stringent tolerances to optimize the
overall efficiency and performance
As such it is important to accuratelymodel design operate and moni-
tor performance characteristics of any
impellers diffusers return channels
and generally all flow-path components
in a compressor with side-stream FC
Amin Almasi
is a senior rotating
machine consultant
in Australia He is
a chartered profes- sional engineer of
Engineers Australia
(MIEAust CPEng ndash
Mechanical) and
IMechE (CEng MIMechE) holds
bachelorrsquos and masterrsquos degrees
in Mechanical Engineering and is
a registered professional engineer
in Queensland He specializes in
rotating machines including cen-
trifugal screw and reciprocating
compressors gas turbines steamturbines engines pumps subsea
offshore rotating machines LNG
units condition monitoring and reli-
ability Mr Almasi is an active mem-
ber of Engineers Australia IMechE
ASME and SPE He can be reached
at aminalmasiymailcom
Amin Almasi
Compressor | Gas Flow | Performance Curve | Side-Stream Flow
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3145
The pressure in the stuffing box
containing the packing can be estimat-
ed by the following equation
SBP = [Discharge ndash Suction] 3 + Suction
Pressure at the bottom of the stuff-
ing box will be higher than the suction
pressure but considerably lower than
the discharge pressure It should be
noted this calculation will yield a con-
servative estimate of stuffing box pres-
sure that can be further reduced by
pump design
A hole in the stuffing box serves as
a port for injecting clean fluid that cir-
culates around a lantern ring aligned
under the flush port The fluid flushes
solids back into the process to protect
the packing from abrasive wear If the
clean fluid is injected at a pressure ex-
ceeding that at the bottom of the stuff-
ing box some of it will leak back into
the process and some will leak out to
the atmosphere Recommended flush
injection pressure is 15ndash30 PSI (1ndash2
Bar) greater than the pressure at the
bottom of the stuffing box
Fluid injection is also used to lubri-
cate and cool dry-running packing that
is subject to frictional heat and to pre-
vent air from entering the pump which
reduces flow and operating efficiency
Centrifugal pumps utilize three
types of impellersmdashopen semi-open
and closed (Figures 2 3 amp 4) Open
designs prevent fluids with large solids
from clogging the impellers but at theexpense of pump efficiency Backing
plates on semi-open designs serve to
trap the fluid for more efficient opera-
tion Closed impellers are for use with
clean fluids since solids could ac-
cumulate in the eye which would re-
quire tearing down the pump to remove
them
Single-Stage CentrifugalPumpsSingle-stage centrifugal pumps typi-
cally have good bearing support of the
shaft with few run-out or ldquowhiprdquo prob-
lems However in some cases they
are subject to cavitation This occurs
in the eye of the impeller where the
fluid is under vacuum If the pressure
is low enough it will cause the material
to vaporize forming air or water vapor
bubbles As the fluid passes through
How Pumping Systems Design Affects Sealing Performance
By Chris Boss
8 January 2015
Flow Control Magazine
|
Understanding how different types of pump designs impact
sealing is critical to optimizing efficiency safety and lon-
gevity of the sealing system Used for a wide variety of media
including clear fluids solutions and slurries single-stage
centrifugal pumps are one of the most common
types (Figure 1) Fluid drawn into these pumps
enters the eye of an impeller that spins itto the outside of its container
or volute building pressure as
it moves toward discharge
Some of this fluid will work
its way behind the impeller
where it must be sealed with
compression packing or a
mechanical seal
Figure 1
Figure 2 Figure 3 Figure 4
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3245
the pump under increasing pressure
these bubbles implode sending shock
and vibration through the impeller
adversely affecting the seal This phe-
nomenon can be mitigated by running
the pump at slower speed and higher
pressure at the suction end to prevent
air from entering the fluid
Double-Ended Split-CasePumpsOperating on the same centrifugal prin-
ciple but slightly different geometry are
double-ended split-case pumps (Figure
5) Fluid enters both ends of the pump
and is directed into the eye of an impel-ler which spins it out of the volute to
discharge Packing is installed on both
the shaft and bearing ends so the stuff-
ing box is exposed only to suction pres-
sure which is usually quite low
Axial Flow Pumps Axial flow pumps operate like hydro
turbines in reverse whereby a propeller
(or axial impeller) pushes the fluid to
discharge (Figure 6)
Since the stuffing box is located
downstream of the propeller at the dis-
charge end of the pump the packing is
exposed to the full discharge pressure
Vertical PumpsVertical turbine pumps are typically
flange-mounted on a floor extending
downward into a water-filled sump
hole (Figure 7) Available as single- or
multi-stage pumps they feature an
impeller or series of impellers rotated
simultaneously by a single shaft The
impellers increase the pressure of the
upward flow subjecting the stuffing box
to full discharge pressure
Vertical pumps can be quite long so
inadequate bearing support can cause
the shaft to run out This can induce
undesirable lateral motion on the pack-
ing Worse the packing may be forced
to serve both as a bearing and a seal To
withstand these conditions the packing
should be resilient elastic and resistant
to deformation These properties rule
out packing such as graphite foil in favor
of fiber-based materials
Multi-Stage PumpsMulti-stage pumps are used for high-
pressure applications such as feeding
the boilers in steam-powered generating
plants Stuffing box pressure can vary
with pump design and number of stag-
es Designed for clean fluids and high
operating speeds these pumps typically
have high- and low-pressure ends with ahydraulic pressure equalization line run-
ning between the stuffing boxes
Like vertical pumps multi-stage
pumps feature a series of impellers to
build fluid discharge pressure In the
case of the six-stage pump pictured in
Figure 8 fluid enters at the drive end
where a stuffing box is exposed to suc-
tion pressure Channeled from one
impeller to the next through the pump
casting the fluid can reach extremely
high pressures at discharge
A second stuffing box located at the
bearing end is exposed to an intermedi-
ate pressure from the third impeller This
pressure is greater than the suction pres-
sure but much less than the discharge
pressure which can reach 2000 PSI
Fortunately the stuffing boxes in
these pumps are not exposed to dis-
charge pressures and typically see be-
low 500 PSI which is within the range
of some packing materials
wwwflowcontrolnetworkcom January 2015 29
Figure 5
Figure 6
Figure 7
Figure 8
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 33450 January 2015
Flow Control Magazine
| Gear PumpsPositive-displacement or gear pumps
operate on a different principle than
centrifugal pumps In external gear
pumps the fluid flows around the out-
side of the gears the intermeshing
of which forces it through the pump
to discharge (Figure 9) This design
makes these pumps particularly suit-
able for use with highly viscous fluids
such as resins emulsions syrups and
adhesives As such they are used for
transfer or metering applications
It should be noted gear pumps will
continue to displace fluid as long as
their shafts are turning which can pose
a problem if a clog occurs at the dis-
charge The resulting buildup of pres-
sure can blow out seals and damage
the pump Therefore most gear pumps
have pressure relief valves to divert
fluid back to the suction side for re-
circulation through the pump Internal
gear pumps operate slightly differently
but also have pressure relief valves to
prevent damage from excessive pres-
sure (Figure 10) In both external and
internal gear pumps the maximum
stuffing box pressure is determined by
these valves
Other rotating equipment includes
mixersagitators which are similar to
pumps in terms of the speeds to which
the packing is exposed There are ba-
sically three types of mixersagitators
top- bottom- and side-entry Top-entry
models are subject to the same con-
cerns about shaft run-out ldquowhiprdquo and
lateral forces on the paddles that are
encountered in some vertical pumps
Although some fluid may splash onto
the packing these mixers basically run
dry so the packing must have the abil-
ity to dissipate the resulting frictional
heat
In bottom-entry mixers the packing
is always exposed to fluid and may also
be exposed to solids requiring abra-
sion-resistance If the seal fails the en-
tire contents of the tank will eventually
drain out onto the bearings the floor
and other components under the stuff-
ing box
The packing in side-entry mixers may
be fully or intermittently exposed to flu-
id as well as side loading and vibration
Aside from media temperature
speed and other application variables
the configurations and operating prin-
ciples of rotary-type pumps exert differ-
ent forces on the seals used to keep
them from leaking These forces can
spell the difference between accept-
able seal performance and failure
Understanding these differences has
important implications that should be
taken into account to assure proper
sealing selection for long-term trou-
ble-free performance FC
wwwgarlockcom
Chris Boss is
a senior applica-
tions engineer for
Garlock Sealing
Technologies in
Palmyra NY He
has held various
positions in produc-
tion engineering
product development and applica-
tions engineering for the companyrsquos
compression packing division He
is a BSME graduate of the State
University of New York at Buffalo Mr
Boss can be reached at 800 448-
6688 or chrisbossgarlockcom
Chris Boss
Cavitation | Centrifugal Pump | Pump Packing | Sealing System
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Figure 9
Figure 10
Aside from media temperature speed and
other application variables the configurations
and operating principles of rotary-type
pumps exert different forces on the seals used
to keep them from leaking These forces can
spell the difference between acceptable seal
performance and failure
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3445
NS IDERNDUSTRIAL AUTOMATION + PROCESS CONTROL
WANT
INFORMATION
ON THE
automationindustry
SUBSCRIBE NOW at wwwiainsidercouk
Published by Spitzer and Boyes LLC Write in 15 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3545
Frost says the push from developing
economies is important as the market
is technologically mature and seeing
restricted growth in developed econo-
mies This is particularly true in Europe
and North America where recent finan-
cial insta-
bility has
reduced capital expenditure across end-
user industries
Bill Moore senior vice president of
sales development and channel man-
agement for global bearings manufac-
turer SKF says ldquosmartrdquo products and
the expansion of robust reliability pro-
grams are helping to drive new invest-
ment particularly in developed coun-
tries where the cost to compete is
high Frost says the magnitude of
the existing global installed base will
strengthen the need for replacement
and upgrades adding to market de-
mand as well
Frost says despite the potential
in developing economies the focus
on price as a product differentiator
may lead to intense price pressures
among manufacturers and bring down
the value of the overall market in the
short term The growing trend among
consumers to choose low-cost Chinese
imports will complicate this challenge
As price and quality become stan-
dardized across the globe customers
will base more of their purchasing deci-
sions on value-added services accord-
ing to Frost This will push manufactur-
ers to create more maintenance-free
solutions such as lubrication-free
bearings that offer end-users savings
on service and replacement costs and
reduce downtimeldquoOffering a complete line of prod-
ucts with comprehensive services will
be another feather in the cap of ven-
dors looking to widen their consumer
baserdquo notes Frost Industrial Automa-
tion and Process Control Research
Analyst Guru Mahesh
Moore says the trend of outsourcing
manufacturing to regions where labor
and production costs are favorable is
becoming less of a factor
ldquoThe days when cheap labor made
a significant difference in where a prod-
uct is manufactured mdash particularly high
value-added products or high weight
and bulk products mdash are coming to
an end as the cost of transportation
storage and inventory balance out the
benefits of production costs where la-
bor is a smaller percentage of the cost
of manufacturingrdquo Moore says ldquoLocal
manufacturing development will indeed
come to developing countries as their
ability to create markets that generate
economies of scale that support local
production is a clear trend and one that
all manufacturers will pay attention tordquo
Moore says that development of
maintenance-free or predictive tech-
nologies and products will be a sig-
nificant advantage to everyone in the
Bearing amp Coupling Manufacturers Focus
onDEVELOPING Economies
amp EFFICIENCY InnovationBy Amy W Richardson
2 January 2015
Flow Control Magazine
|
gy
Anew study from Frost amp Sullivan (wwwfrostcom) fore-
casts steady growth for the overall bearings and couplings
market based on rapid industrial development in high-growth
regions Specifically Frost predicts development in Mexico
Indonesia Nigeria Turkey Brazil Russia India and Chinawill help boost the bearings amp couplings market from $2206
billion in 2013 to an estimated $2676 billion in 2018
The development of maintenance-freeor predictive technologies will helpboost growth in the bearings market For example SKF is developing products that will automatically notifyusers when a bearing or mechanicalrotating component is approachingthe end of its useful life Pictured hereis an SKF Microlog analyzer a por- table condition monitoring tool
COURTESY SKF
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
improved productivity through simplified solutions The powerful technology and tools ensure repeatable
reliable accurate measurements Easier access to process data allows for better troubleshooting process
optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
For daily product notes visit the lsquoFeatured Productsrsquo section flowcontrolnetworkcom
ON THE WEB
1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3845
FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
and benefits as well as grids of
instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
services provided for the
mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
Brought to you by Beamex
Your Source For Fluid Handling Videos
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Select appropriate issue ofFlow Control Magazine
Select advertisements thatinterest you
Enter your email amp clickldquoSubmit Requestrdquo
1
2
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4
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ONLINE
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7232019 Flow Control January 2015
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THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
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Title _________________________________________________________________
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AddressCityStateZip __________________________________________________
______________________________________________________________________
Phone ________________________________________________________________
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One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545
![Page 3: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/3.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 345
The only press fittings in multiple materials
The g lobal leader
in plumbing heat ingand p ipe jo in ing systems
Industrial press fitting solutionsfor clean controlled installations
Do more with Viega press fitting solutions
for hundreds of applications Make the
same press connections for copper
stainless and black iron along with
easy-to-install transition fittings
Only Viega can provide all of your system
installation needs Viega connections can
be made in seconds wet or dry so lengthy
shutdowns become a thing of the past
and system maintenance and repair is
easier than ever Whatever your industrial
installation needs Viega has the answers
bull Only Viega offers the patented
Smart Connectreg feature toidentify unpressed connections
bull More than 1400 tting choices
in copper stainless and carbon steel
bull Viega ProPressreg and Viega MegaPressreg
fittings have been tested to the strictest
standards in North America
bull Viega MegaPress the only carbon steel
press solution for water and gas
bull No ame is required to install Viega
products eliminating noxious fumes
hot work permits and fire watches
wwwviegaus | 1-800-976-9819
Write in 1 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 445
Do you need flow measurement with online density compensation
Available now with OPTISWIRL 4200 from KROHNE
Featuring integrated pressure and temperature sensors the new OPTISWIRL 4200
vortex flowmeter provides online density compensation for all types of gas and steam
The OPTISWIRL 4200 even masters fluctuating operating conditions with effortless
precision and helps to significantly reduce installation costs Itrsquos the smart choice for
auxiliary and supply processes in a broad range of applications
Developed for use in continuous volume flow measurements in safety-related
applications the OPTISWIRL 4200 is in full compliance with the IEC 61508 SIL2 safety
standard Units can be easily switched from non-SIL mode to SIL mode without the need
to call out a service technician
Minimising downtime is critical for your business Thatrsquos why the OPTISWIRL 4200
provides redundant data storage of all calibration and configuration data in the display
memory and the electronics module ndash transferring data to replacement modules is a snap
When efficiency and flexibility matter most the OPTISWIRL 4200 is the definitive choice
KROHNE ndash Flow measurement is our world
Please see our website for more information
The All-in-OneSolution
Write in 2 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 545
featurescontents
16 The Two-Wire Advantage
By Steve Milford Advances in two-wire instrumentation specifically in relation to flow-
meters have enabled significant cost benefits for new technology in-
stallations in terms of capital investment and cost of ownership
20 Compensating for CompressibilityIn Gas Flow MeasurementBy Kevin Clark
K-factor adjustment is a key factor in ensuring accurate gas flow mea-
surement for inline turbine meters The K-factor is established by an
initial factory calibration In the case of a non-compensated flow moni-
tor any variations in pressure and temperature will require manual
adjustments to the K-factor
2 | January 2015 Flow Control Magazine
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 qualied subscribers Non-qualied subscrip-
tion rates in the US 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 t he Circulation
Manager for more wire transfer information Single copies $10
per issue in the US and Canada Single copies $15 per is-
sue in all other countries All subscription payments are due in
US funds
POSTMASTER Send address changes to Flow Control PO BOX
2174 Skokie IL 60076-7874 Periodical postage rates paid at
Subscription Information Toll Free 8667214807Outside US 8477631867Mail PO Box 2174Skokie IL 60076-7874E-mail flowcontrolhalldatacom
SubscribeRenewChange of Addresswwwflowcontrolnetworkcomsubscribe
Birmingham AL 35242 and additional mailing ofces
copy Entire contents copyright 2015 No portion of this publica-
tion may be reproduced in any form without written permis-
sion of the publisher Views expressed by the bylined con-
tributors should not be construed as reecting the opinion
of this publication Publication of productservice information
should not be deemed as a recommendation by the publisher
Editorial contributions are accepted from the uid handling
industry Contact the editor for details Productservice infor-
mation 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
1 616
Pumps Bearings amp Seals Technology Report SPECIAL SECTION PAGE 23
24 The Complicated Case of Compressors
with Side-StreamsBy Amin Almasi
28 How Pumping Systems Design AffectsSealing PerformanceBy Chris Boss
32
Bearings amp Couplings Suppliers Position
to Drive Market GrowthBy Amy W Richardson
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 645
Do you know whatrsquos
gone out the window
at your facility
Magnetrolreg energy management solutions monitor and measure the energyflowing through your facility to reduce utility costs and make processes moreefficient Easy to install and operate TA2 thermal flow meters provide you withan efficient environmentally responsible way to manage compressed air andnatural gas cost centers
Make MAGNETROL Thermatel reg TA2 mass flowmeters part of your energy management strategyVisit magnetrolcomthermalmassflow or contact
your MAGNETROL representative for more information
Measure and control your compressed
air and natural gas energy costs with
Thermatelreg TA2
991266 PDJQHWUROFRP Write in 3 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 745
1 9 9 5 - 2 0 1
51 9 9 5 - 2 0 1
5
20th20th january 2015 | Vol XXI No 1
4 | January 2015
Flow Control Magazine
departmentscolumns6 EDITORrsquoS FILE
4 flow things you need to know aboutthis month
14 APPLICATIONS CORNERa coriolis mass flowmeter providesa better solution
39 WORD SEARCH temperature measurement
40 QUIZ CORNER how to calculate orifice plate flow rate
Cover imagesFlowmetercourtesyEndress+HauserBackgroundiStock
8 NEWS amp NOTES api 624 valveemissions update intelligent features toboost desal pumps market hydraulic fractur-ing water treatment on the rise
34 UP CLOSE with Micro Motionrsquos Model5700 Coriolis Transmitter
35 NEW PRODUCTS
36 WEB RESOURCE FILE
38 ADPRODUCT INDEX
S I N C E 1 9 5 8
Itrsquos More than a Check Valve
Itrsquos a Check-All
When You Need Absolute Precision
CHECK-ALL IS THE ONLY CHOICE
Our spring loaded check valves are assembled
to your exact needs ensuring absolute precision
and reliability They work like they should Plus
most lead times are less than one week Thatrsquos
what makes Check-All the only choice
Get me a Check-AllManufactured in
West Des Moines Iowa USA515-224-2301 bull salescheckallcom bull wwwcheckallcom
Write in 4 or Request Info Ins tantly at wwwFlowControlNetworkcomfreeinfo Write in 5 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
Return on investment calculations for plant upgrade or new
plant construction projects may go through several iterationsbefore the trigger is finally pulled or indeed not pulledldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 845
The new Ultratrade 8c The capability and performance
your market demands
Copyright copy FMC Technologies Inc All Rights Reserved
FMC Technologiesrsquo Ultra 8c ultrasonic owmeter shares the advanced technology
of the next generation Smith Meterreg Ultra Series meters With its touchscreen
interface upgradable memory and high-speed processor the Ultra 8c provides
cutting-edge performance and diagnostic ability And with additional measurement
paths the Ultra 8c has even better cross-ow and swirl compensation for improved
accuracy and repeatability Whether for leak detection or custody transfer theUltra 8c gives you the assurance of superior performance in the eld even for the
most viscous crude oils in todayrsquos market
For more information visit wwwfmctechnologiescomultrafc
wwwfmctechnologiescom
Write in 6 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 945
20 Years of Flow Control This
year marks the 20th Anniversary of
Flow Control magazine Launched
in 1995 with the aim of serving technical
professionals involved with designing oper-
ating and maintaining fluid handling systems in a wide range of
industries Flow Control has leveraged its many years of experi-
ence to establish a unique niche and reputation for providinghigh-quality information to you our subscribers I congratulate everybody who helped
Flow Control get to where it stands today Herersquos to another 20 years of success
Training Time Itrsquos a new year and we have two new
training opportunities for
you to enhance your skillset in 2015
Regular Flow Control columnists Da-
vid W Spitzer and Larry Bachus will
be presenting three-day courses on
Flow Measurement and Pumping
Systems respectively I encourage you and your colleagues to take ad-
vantage of these important training
opportunities For more details see
flwctrlcomflowseminar amp
flwctrlcompumpguy
Oil amp Gas Gender Gap Results of a
new global workforce survey conduct-
ed by OilCareerscom and Air Energi
show a gender gap in the oil amp gas industry
persists despite ongoing efforts to recruit more
women into the industry According to hiring
managers the
top three factors
that significantlycontributed to
the gender gap
in the oil amp gas
industry are
1 A lack of women entering the industry (55
percent)
2 An industry culture created by a male-domi-nated environment (53 percent)
3 The logistics requirement ie travel shift
and working patterns in the field (30 percent)
For more on this story and an infographic seeflwctrlcomog_gendergap
Rockwell Automation Fair 2014 Our colleagueKevin Parker at Processing magazine attended the
annual Rockwell Automation Fair Nov 9-10 in
Anaheim Calif Parker gleaned some interesting perspec-
tive on key trends in process automation including
1 Hardware and software are more blended than ever
2 Fog computing (a kind of cloud computing) is making
headway in industrial engineering environments where latency is a critical concern
For Parkerrsquos full report from the Automation Fair see flwctrlcomrockwellfair2014
DITORrsquoS FILE
6 | January 2015
Flow Control Magazine
4 Flow Things You Need to Know
GROUP PUBLISHERPROCESSINGFLOW CONTROL
MICHAEL C CHRISTIAN | (908) 507-5472mikecgrandviewmediacom
NATIONAL ACCOUNTS MANAGERJIM SEMPLE | (908) 963-3008 jsemplegrandviewmediacom
EXECUTIVE DIRECTOR OF CONTENTMATT MIGLIORE | (610) 828-1711
mattgrandviewmediacom
MANAGING EDITOR AMY W RICHARDSON | (205) 408-5050
arichardsongrandviewmediacom
COLUMNISTS
LARRY BACHUSDAVID W SPITZER JESSE YODER
ART DIRECTORJULIE FLYNN
juliegrandviewmediacom
MANAGER - DIGITAL OPERATIONSMARY BETH ROMANO
SUBSCRIPTION amp REPRINT REQUESTSflowcontrolhalldatacom
Administrative TeamGENERAL MANAGER
BARRY LOVETTE
CHIEF OPERATIONS OFFICERBRENT KIZZIRE
VICE PRESIDENT OF FINANCEBRAD YOUNGBLOOD
VICE PRESSIDENT OF B2B GROUPMIKE WASSON
CHIEF REVENUE OFFICERCHRIS DOLAN
VP AUDIENCE DEVELOPMENTDELICIA POOLE
AUDIENCE DEVELOPMENT MANAGER ANNA HICKS
DIGITAL AUDIENCEDEVELOPMENT ANALYST
STACY BARNES
EDITORIAL ADVISORY BOARDLarry Bachus Bachus Company IncGary Cornell Blacoh Fluid Control
Jeff Jennings Equilibar LLCMitch Johnson JMS SoutheastPeter Kucmas Elster Instromet
Jim Lauria Water Technology Executive
John Merrill PE EagleBurgmann IndustriesSteve Milford Endress+Hauser US Tom OrsquoBanion Emerson Process
Management Micro MotionDavid W Spitzer PE Spitzer and Boyes LLC
Tom Tschanz McIlvaine Company John C Tverberg Metals and Materials
Consulting EngineersJesse Yoder PhD Flow Research Inc
WINNER
WINNER WINNER
PERSPECTIVES FROM THE MONTH THAT WAS IN THE WORLD OF FLOW CONTROL
WINNER WINNER
THE
NETWORK
1
2 3
4
1 9 9 5 - 2 0
1 51 9 9 5
- 2 0 1 5
20th20th
Matt Migliore Executive Director of Content MattGrandViewMediacom
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1045
Endress+Hauser Inc
2350 Endress Place
Greenwood IN 46143
infousendresscom
ww wusendresscom
Sales 888-ENDRESS
Service 800-642-8737
Fax 317-535-8498
Guided wave radar level products - built for safety precision and efficiency
bull Reliable non-contact measurement even for changing process conditions
bull HistoROMreg data management - concept for fast and easy
commissioning maintenance and diagnostics
bull Multi-Echo Tracking evaluation - highest reliability even with the
presence of obstructions in the vessel
bull Hardware and software developed according to IEC61508 up to SIL3(in homogeneous redundancy)
bull Seamless integration into control or asset management systems
bull Worldrsquos easiest proof test concept for SIL saves time and cost
wwwusendresscommicropilot-radar-level
The newest generation of Micropilot
Taking your process to the next level
Write in 7 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1145
HE OUTLOOK | News amp Notes
1 ISO15848 ldquoMeasurement test and qualification proce-
dures for fugitive emissionsrdquo
a Part I ndash ldquoClassification system and qualification proce-dures for type testing of valvesrdquo
b Part II ndash ldquoProduction acceptance test of valvesrdquo
2 API 622 ldquoType Testing of Process Valve Packing for Fugitive
Emissionsrdquo
3 End-user defined fugitive emission reduction requirements
Key aspects of valve testing per API 624 include
The standard covers rising and rising-rotating stem
valves up to 24rdquo diameter
Class 1500 valves are not covered
The test medium is methane
310 test cycles are required with three thermal cycles Temperature application range is from -29 C to 538 C
with last cycle 10 cycles user-defined (can be -45 C)
Re-tightening of gland bolts is not permitted during test
Valve stem test orientation is vertical
Several valves must be tested to achieve API 624 com-
pliance Similar industry principles applied to test valves
qualify two nominal sizes smaller one size larger and one
pressure class below
Allowable leakage is 100 PPM maximum
Gate and globe valves need to be tested separately
For example Gate Valves per API602 four tests API600
eight tests (up to 20rdquo diameter) API 603 eight tests andfor Globe Valves per API 602 four tests
Test valves should be production valves not specially
manufactured test valves
As a result of the release of API 624 testing companies have
been gearing up for an increase in the number and size of
test valves and new test houses are coming to market Withthis in mind implementation of API 624 needs to be carefully
monitored and claims from valve manufacturers should be
validated by requesting to view test results Important factors
to be mindful of include
Number of cycles on some valves could be detrimental
to packing as certain smaller size valves donrsquot come with
grease ports to keep the stem lubricated all of the time
Test failures of valve stem threads yokes and glands
Grease traps into packing and causes leakage
At higher temperatures a few greases create volatile
organic compound and burn off
Testing in vertical generates more heat in yoke area
Certain challenges need a good testing company that has
experience in testing on fugitive emissions and provides
guidelines to manufacturers in terms of use of packing valve
grease testing requirements etc
A preliminary survey was conducted with end-users regard-
ing current utilization and application of API 624 For a sum-
mary of responses from this survey visit flwctrlcom1oWijWz
Gobind Khiani PEng is with Fluor Canada Ltd Khiani has
spent 20-plus years in the energy and power business and 10-
plus years in the Western Canadian oil and gas industry Hecan be reached at 403 850-6982 or gobindkhianifluorcom
Valve Standards UpdateEnd-users ramp up compliance efforts for API 624
as new specifications emerge on the horizon
8 | January 2015
Flow Control Magazine
By Gobind Khiani
In the May 2014 issue of Flow Control (page
16) the new standard API 624 ldquoType Testing
of Rising Stem Valves Equipped with Graphite
Packing for Fugitive Emissions First Editionrdquo was
addressed This standard which was published
and put into effect in February 2014 estab-
lishes guidelines for testing industrial valves for
emissions compliance Since the publication ofthe May article further requests from industry
have spurred the creation of another specifi-
cation API 641 ldquoType Testing of Quarter-Turn
Valvesrdquo and an API ldquoPiping and Valvesrdquo commit-
tee has been formed Regulators and end-users
are also working on
1992 1998 2003 2008 2013 2020
4
35
3
25
2
15
1
05
0
M i l l i o n o f
t o n n e s y e a r Will API 624
have a stepeffect in reducing
fugitiveemissions
Global valve fugitive emissions
End User response at best
End User response actual
S O U R C E G O B I N D K
H I A N I
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1245
Intelligent Features to Boost Global WaterDesalination Pumps Market
The Global Water Desalination
Pumps Market is expected to grow
at a CAGR of 77 percent from 2015 to
2019 according to a new report from
TechNavio (wwwtechnaviocom)
The report shows demand for water
treatment has increased significantly in
developing countries where fresh wa-
ter resources can be scarce Providing
clean and potable water to huge popu-
lations has become a priority which is
pushing the demand for water desalina-tion pumps in the market according to
TechNavio
The report emphasizes the emer-
gence of intelligent pump systems as
a major driver of market growth In-
telligent pumps possess the ability to
regulate flow and pressure and these
systems can automatically adjust to
process and pump system changes
ldquoIntelligent pump systems are be-
ing adopted by many manufacturers
because of the high level of fault toler-
ance ability which leads to a significant
reduction in the total cost of owner-
shiprdquo said Faisal Ghaus vice president
of TechNavio in a news release ldquoThe
adoption of these systems will also
help industries comply with current Eu-
ropean Union regulations in relation toreduction in energy consumptionrdquo
The growing demand for clean wa-
ter worldwide will continue to augment
the demand for water desalination sys-
tems which will propel the Global Water
Desalination Pumps Market during the
forecast period
trendlines
wwwflowcontrolnetworkcom January 2015 | 9
Write in 8 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
Intelligent pump sys-tems are being adopt-
ed by many manufac-
turers because of the
high level of fault tol-
erance ability which
leads to a significant
reduction in the total
cost of ownership
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1345
HE OUTLOOK | News amp Notes
10 | January 2015
Flow Control Magazine
Hydraulic Fracturing WaterTreatment amp Reuse Expected to Soar
Wastewater treatment spending for
hydraulic fracturing is expected to
grow almost three-fold from $138 mil-
lion in 2014 to $357 million in 2020 in
the US according to a new report from
Bluefield Research
The US hydraulic fracturing industry
consumes over 1 billion barrels of wa-
ter annually producing 450ndash500 mil-
lion barrels of contaminated water for
disposal with only about 14 percent
treated and reused Bluefield cites watersupplies increasingly at risk tighter regu-
lations emerging in key states and costs
of disposal on the rise as factors con-
tributing to the substantial rise in water
treatment and reuse which is expected
to account for 27 percent of total pro-
duced and flowback water by 2020
Overall the US hydraulic fracturing
industry will spend $638 billion in 2014
on water management Water transport
and disposal costs will account for 66
percent of the total water managementspent this year with treatment compris-
ing roughly 2 percent
Bluefield reports water scarcity in
Western US states has had little im-
pact to date on fracturing water supply
but that is likely to change if droughts
persist Meanwhile state regulators are
beginning to tighten control of produced
water disposal In Pennsylvania where
policymakers in 2010 placed discharge
limits on wastewater from unconven-
tional oil amp gas operations statewide
treatment and reuse rates for the Mar-
cellus jumped to 90 percent in 2014
The increasing cost of transport and
injecting water into wells mdash now ac-
counting for 66 percent of water servicesspending mdash and the improving cost
structures of treatment provide another
driver of reuse Bluefield reports Well
operators that employ treatment and re-
use solutions spend on average $880
per barrel of water used compared to
$1020 per barrel of water trucked and
injected into wells although cost com-
parisons are site specific
ldquoFracking has been the Wild West for
the US water industryrdquo said Reese Tis-
dale president of Bluefield Research ina prepared statement ldquoThere are three
reasons for this first there has been
an explosive build-out of fracking well
installations now surpassing 126000
Second there has been a lack of clear
regulation on water management in key
markets And third there is not a one-
size-fits-all treatment solution for frack-
ing meaning solutions providers have
had to ascend a steep learning curve
to treat the variable wastewaters that a
single well is capable of producingrdquo
Tisdale notes that these inhibitors
while still acute are beginning to take on
a new form This is partially due to signifi-
cant gains in water management experi-
ence realized adoption of more efficientwater management strategies among
well operators and the emergence of
new policy mechanisms from regulators
that are playing catch-up with the fast-
moving hydraulic fracturing industry
trendlines
Treatment2
Disposal
6
Supply10
Storage22
Transport60
US $638Billion
S O U R C E B L U E F I E L D R
E S E A R C H
Write in 23 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
Industry-Leading
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bull Probe type industrial RTDsbull Electronic temperature switchtransmitter bull Vapor-actuated remote thermometersbull Digital temperature indicatorsbull Platinum resistance temperature transmitterbull Compact OEM temperature transmitter bull Industrial amp instrument type bimetal thermometersbull Thermowells
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1445
New Technique Could ReduceEnergy Required for Oil Refinement
UK scientists have developed a
technique they say has the poten-
tial to dramatically reduce the amount
of energy required for the refinement
of crude oil
Professor Martin Schroumlder and Dr
Sihai Yang from The University of Not-
tingham (wwwnottinghamacuk ) have
led a multi-disciplinary team of scien-
tists from Nottingham the Science and
Technology Facilities Councilrsquos (STFC)
ISIS Neutron Facility Oak Ridge Na-tional Laboratory and Diamond Light
Source to discover a porous material
that works like a chemical sponge to
separate a number of important gases
from mixtures generated during crude
oil refinement
According to a news release from
The University of Nottingham the ex-
isting industrial process uses ldquohuge
amounts of energy to separate and pu-
rify these gases so the new technique
has the potential to revolutionize the oil
industry by significantly reducing car-
bon emissions and making the process
more environmentally friendlyrdquo
Commercially UsefulCrude oil is a raw material that is
refined to produce fuel for cars toheat homes and to create polymers
and other useful materials It is made
up of a complex mixture of hydro-
carbons (chemical compounds that
contain only hydrogen and carbon) of
which certain components are espe-
cially commercially useful
One industrial process used to
achieve hydrocarbon separation is
called ldquocryogenic distillationrdquo which is
widely used worldwide and uses vast
amounts of energy to generate the high
pressures and cryogenic temperatures
required to ensure efficient separation
research amp development
wwwflowcontrolnetworkcom January 2015 | 11
PLASTIC CONTROL VALVES FORALL YOUR CORROSIVE APPLICATIONS
PO Box 938 bull Angleton TX 77516Tel (979) 849-8266 bull wwwcollinsinstcom
Collins plastic control valves are
highly responsive control valves
designed for use with corrosive
media andor corrosive atmos-
pheres
Collins valves feature all-plastic
construction with bodies in PVDF
PP PVC and Halar in various body
styles from 12 - 2 with Globe
Angle or Corner configurations and
many trim sizes and materials
Valves may be furnished without
positioner for ON-OFF applications
Call for more information on our
plastic control valves
Write in 9 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1545
of hydrocarbon mixtures into pure components
However researchers say an innovative solution may
have come in the form of a novel chemical sponge This
porous material a metal-organic framework was devel-
oped by the same team at Nottingham just two years ago
Now in research published in Nature Chemistry for the
first time scientists have proven that it can be used toseparate hydrocarbon mixtures without the need for high
process pressures or very low process temperatures
Reusable MaterialsMade from cheap organic materials aluminum nitrate
salt and water the porous material called NOTT-300 is
able to adsorb different gases found in mixtures of hydro-
carbons at different rates making it possible to sepa-
rate them and extract the most useful ones NOTT-300
requires less energy to function than existing methods
as it operates at ambient temperatures and normal pres-
sures researchers say The gases that are adsorbed intoNOTT-300 can be removed without a significant energy
input and therefore the material can be easily reused
The team of scientists from Nottingham used Diamond
the UKrsquos synchrotron science facility as well as STFCrsquos
ISIS Neutron Facility and Oak Ridge National Laboratory
the UKrsquos and USArsquos world-leading neutron facilities re-
spectively to prove that the sponge works under real-life
conditions
Professor Martin Schroumlder Dean of the Faculty of Sci-
ence at Nottingham said in the news release ldquoIt is a very
important to be able to separate different hydrocarbons ef-
fectively and efficiently with low-energy consumption Po-rous solids such as the metal-organic framework system
studied here represent important materials for the future
development of low-energy separation technologies We
are most grateful to our collaborators at ISIS Neutron Fa-
cility Oak Ridge National Laboratory and Diamond Light
Source in bringing this work to fruitionrdquo
Significant Impact on Oil IndustryDr Sihai Yang the winner of Diamond Young Scientist
and BTM Willis Prize is a Senior Research Fellow at
Nottingham He led the project together with Professor
Martin Schroumlder Yang said ldquoWith the help of advancedcentral facilities like Diamond ISIS and ORNL we have
developed a new separation technique which can poten-
tially reduce the energy usage associated with oil petro-
leum and chemical industries which require the separa-
tion of raw hydrocarbons from crude oil
The discovery of the new material NOTT-300 could
have a significant impact on the oil industry by removing
the necessity for some energy-intensive refinement pro-
cesses researchers say
The research was funded by Engineering and Physical
Sciences Research Council (EPSRC) the European Re-
search Council (ERC) The University of Nottingham andLeverhulme Trust
12 | January 2015
Flow Control Magazine
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No media contact - No risk of leaks
No process Shut-Downs for installation
No bypass needed
For hazardous area locations (FM approved)
Monitor your Total Acid Consumption
Increase your Plant Up-Time
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PIOXreg S
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Non-intrusive mass flow concen-
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of aggressive media
wwwpiox-scom
wwwfleximcom
Contact us for a free trial measurement
Thank you for your votes and
making PIOXreg S a Flow Control
Awards Winner
THE OUTLOOK | News amp Notes
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1645
The ASCO trademark is registered in the US and other countries The Emerson logo is a trademark and service mark of Emerson Electric Co copy 2014 ASCO Valve Inc
1-800-972-ASCO (2726) | e-mail info-valveascocom | wwwascovalvecomSpoolValve
Now get spool valves with industry-leading ASCO solenoid technology built in
Delivering unmatched performance and durability our compact new valves are
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range of easily configured features and options includes superior temperature and
pressure ratings plus low-power models The industryrsquos toughest testing ensures
every rugged stainless steel valve meets or exceeds specifications Plus we design
and support every spool valve we make Ask for ASCO the ultra-reliable choice for oil
and gas control panels
These new spool valves will fit right in
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 174514 | January 2015 Flow Control Magazine
PPLICATIONS CORNER | Process Instrumentation
This is the final article in a series based on the troubleshoot-
ing of a mysterious unit shutdown due to flowmeter perfor-
mance problems
If yoursquove followed this column for most of 2014 you know
that what should have been a liquid ammonia stream to the
feed plant became problematic due to the occurrence of
bubbles of ammonia gas These bubbles caused an ultrasonic
flowmeter in a unit to indicate zero flow and caused the reactor
to scram (shut down) under warm operating conditions The source of the bubbles was traced back to the pres-
sure drop associated with a control valve located at the
exit of the liquid ammonia tank farm
This issue was resolved by identifying the problem
and fixing it at its source This was a pragmatic ap-
proach at the time (early 1980s) given the operation
of the cooling system in the unit and the limited selec-
tion of applicable flowmeter technologies
By the early 1990s changes were implemented that elim-
inated all process cooling requirementsmdashexcept for the small
jacketed cooler upstream of the liquid ammonia flowmeter In
other words after these changes the entire cooling system
would be operated and maintained to cool a few meters of
one small ammonia pipe Coincidently at about the same
time Coriolis mass flowmeters became more mature and
could reasonably measure the mass flow of liquid streams
with homogeneous low levels of vapor
The convergence of these two events resulted in another
approach to the problem that was not available in the early
1980smdashie install a Coriolis flowmeter that could operate in
the presence of bubbles The purchase and installation of a
Coriolis mass flowmeter was given high priority given its im-pact on unit operation economics and safety (by eliminating
the ldquomidget-makerrdquo (see March 2014 page 14))
Plant requirements and the technology that can meet
plant needs keep changing An excellent solution today can
become outdated in just a few years However there are few
substitutes for understanding fundamentals when addressing
a problem In other words there can be more than one way
to skin a cat FC
wwwspitzerandboyescom
Problem Solved AgainA Coriolis mass flowmeter provides a better solution
F o r B e t t e r P i p i ng S y s t e m P e r f o r m a nc e hellipFor Better Piping System Performancehellip
I d e a l f o r Ag g r e s s i v e C h e m i c a l s
1384 POMPTON AVENUE CEDAR GROVE NEW JERSEY 07009
973-256-3000 bull Fax 973-256-4745www p l as t om a t ic co m bull i n f o p la s t om a t ic co m
bull Rugged thermoplasticshandle corrosive andultra-pure chemicaltreatments
bull Constant pressure enhances
pump performancebull Prevents overpressure in
piping system
bull Wide range of pressuresettings
bull PTFE shaft and diaphragm designs
bull 1 4rdquo - 3rdquo sizes in PVC CPVC PVDFPolypro and PTFE
bull First State approved
thermoplastic valve for
anti-siphon applications
Write in 10 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
David W Spitzer
Ammonia Gas | Coriolis Flowmeter | David W Spitzer | Scram | Troubleshooting
FLOWSTREAM Find related content flowcontrolnetworkcom
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and Boyes
LLC offering engineering seminars strategic marketingconsulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer can be reached at 845 623-
1830 or at wwwspitzerandboyescom
The purchase and installation of a
Coriolis mass flowmeter was given
high priority given its impact on unit
operation economics and safetyldquordquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1845
Smart Valve Positioner
Beyond Control The NEW Research Controlreg SRD positioner does
everything you expect any valve positioner to do
plus more The SRDrsquos comprehensive diagnostics tool
continuously monitors for fugitive emissions delivers
real-time performance statistics and facilitates both
proactive and reactive process management Available
with integrated network communications the SRD is
compatible with Research Control valves and most other
pneumatically-actuated valves
Visit wwwbadgermetercomSmart-Valve-Positioners or
call 877-243-1010 for more information today
copy 2015 Badger Meter Inc
RESEARCH CONTROL is a registered trademark of Badger Meter Inc
Write in 11 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1945
Process improvements to increase yield or cut manufactur-
ing costs typically require enhanced process control but the
installed base of measurement instrumentation in a process
plant may simply be unable to facilitate improvements because
of age inadequate performance or unreliability Maintenance
cost and unscheduled process downtime for an aging process
plant can be very damaging to the balance sheet Upgrading
to new more accurate and more reliable instrumentation can
be prohibitively expensive New plant construction must alsomaintain a focus on optimizing costs for the process control
infrastructure The budget approval decision for new plant
construction must weigh such costs against projected market
conditions for the products that the plant is intended to manu-facture In todayrsquos volatile global marketplace return on invest-
ment calculations for plant upgrade or new plant construction
projects may go through several iterations before the trigger is
finally pulled or indeed not pulled
This article describes advances in two-wire instrumenta-
tion specifically in relation to flowmeters that have taken
place in the past few years and the significant cost benefits
that this new technology can realize for plant builders and op-
erators in terms of capital investment and cost of ownership
The Significance of Two-Wire Loop Power
A survey involving 204 participants in the chemical indus-try across Germany Switzerland the UK Canada and the
United States (Manfred Koenig PhD KIM Ludwigshafen
Germany 2006) revealed an 87 percent preference for two-
wire instrumentation versus four-wire in process applications
and 89 percent for utilities This overwhelming preference
may stem from the fact that older process plants were built
with two-wire twisted-pair cable networks connecting all
process units and measuring instruments together in an
overall plant control scheme
However these existing cables are relatively unsophisti-
cated and incapable of supporting anything but low-energy
instrumentation that is insensitive to interference from otherelectrical sources that might be sharing the same cable con-
duit Further the low energy levels supported by these two-
wire loops are more easily rendered safe in terms of explo-
sive risk in hazardous areas containing flammable materials
Many older process plants are also likely to have a significant
installed base of flowmeters employing pre-war (pre-1945)
technology such as positive displacement (PD) turbine vari-
able area (VA or Rotameter) and differential pressure (dP)
Market data firm Flow Research Inc (wwwflowresearch
com) indicates collectively a future compound negative annual
growth rate approaching minus 3 percent to 5 percent for PD
turbine and VA flowmeter types while dP is expected to keeppace with market growth (World Market for Flowmeters 2010)
YSTEMS DESIGN | Flow Measurement
16 | January 2015
Flow Control Magazine
The Two-Wire
ADVANTAGENew wiring options enable modern instrumentsto drive cost savings in existing plant systems
By Steve Milford
Advances in two-wire instrumentation have enabled mod- ern technology to be employed to the advantage of older
plant and process systems
Some chemical manufacturing plants are
competing for survival not only externally
against other global companies but also
internally among the global facilities of theirown company Other industry sectors face
similar challenges
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2045wwwflowcontrolnetworkcom January 2015 | 17
The Need to Replace Older TechnologiesUntil the 21st century two-wire loops were only able
to support these relatively unsophisticated instruments
which convert their measurement by various means into a
4-20mA output or pulse signal to the control system The
more advanced post-war flowmeter technologies such as
Coriolis ultrasonic or electromagnetic flowmeters have
until just eight years ago required a dedicated power sup-
ply for their function in addition to the output loop and
thus a four-wire infrastructure was required as a minimum
Therefore upgrading older two-wire meter devices to moremodern four-wire technology could require significant
expenditure in terms of the installation of separate power
cables and supply modules
There was a major breakthrough in 2006 when a true
two-wire loop-powered inline liquid ultrasonic flowmeter
was introduced (Figure 1) The nature of this breakthrough
was innovation in device power management This was the
missing piece up to that point because to be a true loop-
powered device the meter had to directly provide a full 16
mA span using less than 36 mA of remaining loop current
and less than 1 Watt of electrical energy The flowmeter
operated on a single 4-20 mA HART two-wire loop wasremotely powered by a DC supply was certified Class 1 Divi-
sion 1 and could be deployed as Intrinsically Safe through
the use of an approved safety barrier
A true two-wire loop-powered Coriolis flowmeter followed
in 2011 (Figure 2) employing a new and more advanced
common electronics platform A two-wire loop-powered inline
ultrasonic flowmeter for low-pressure gas was introduced in
2012 and a second two-wire loop-powered Coriolis meter fol-
lowed in 2013 offering improved measurement performance
and an additional high-performance meter tube material
Electromagnetic and vortex flowmeters had already been
available for some years in two-wire loop-powered form butimproved performance resulted as these designs were incor-
COURTESYENDRESS+HAUSER
Figure 1 A two-wire ultrasonic flow- meter released in 2006 operated ona single 4-20 mA two-wire loop
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omegacom
reg
I I I I LL I
I I I I LL I
copy COPYRIGHT 2015 OMEGA ENGINEERING INC ALL RIGHTS RESERVED
1-888-826-6342
Prices listed are those in effect at the time of publication and are subject to change without noticePlease contact OMEGArsquos sales department for current prices
FPD3000 SeriesStarts at$630
FPD3300 SeriesStarts at
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OSXL-TIM3$999
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Positive Displacement Flow Meterfor Fuels and Oils
bull Aluminum Bodybull FKM Sealsbull Temperatures up to
80ordmC (176ordmF)bull NPT or BSP Threadsbull DIN JIS or ANSI
Connection (Availableon 1 and Larger Sizes)
Positive DisplacementFlow Meter for Solvents
Thermal Imaging CameraFor Inspection andFactory Diagnosis
Note Not for ExportUSA Only
Your One-StopSource for Process
Measurement and Control
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 214518 | January 2015
Flow Control Magazine
porated into their new common electron-
ics platform in 2013 So all the ldquomodernrdquo
flow measurement technologies mdash that
is to say those introduced post-war mdash
have become available as two-wire loop-
powered devices with one exception
namely thermal mass (thermal disper-
sion) meters Unfortunately the power
requirements for this technology exceed
what is currently deemed possible withtwo-wire loop-power management
Payback forTechnology UpgradeConsider a 1rdquo process line
containing a liquid process
ingredient costing $1lb at a
mass flowrate of 150 lbmin-
ute We have $150minute
flowing in the line translating
to $9000hour and $72000
per eight-hour shift That cal-culates further to $360000
per five-day working week and
for a working year of 40 weeks for
example that is $144 million Assume
the existing device is a turbine flowmeter
Now imagine a two-wire loop-
powered Coriolis mass flowmeter is
installed in place of the existing meter
The line would need to be drained and
probably one process flange replaced
allowing the Coriolis to fit mechanically
in place of the turbine However thetwo-wire loop already used for carrying
the existing meterrsquos flow signal to the
control room can be used unaltered
for the complete electrical installation
aspects of the Coriolis flowmeter
The upside of the change is signifi-
cant and clear cut Assuming the exist-
ing meter measurement uncertainty was02 percent of reading then measure-
ment uncertainty improves through use
of Coriolis to 01 percent of reading
giving a 01100 x $14400000 im-
provement in control of the ingredient
annually or $14400 A two-wire Coriolis
mass flowmeter with 01 percent mass
flow accuracy would be paid for in ap-
proximately 6-8 months In practice the
improvement in measurement uncer-
tainty would be greater as the operator
would gain temperature and density in-formation from the Coriolis and the mea-
surement would be devoid of any fluid
property dependence Viscosity change
for example can have a major impact on
turbine meter performance Mechanical
wear and tear that turbine meters even-
tually experience which causes them to
under-register flow is precluded by mod-
ern devices like Coriolis
Furthermore if the process ingredient
was being blended with another then ad-
ditional process improvements could berealized through in-line blending control
using Coriolis technology for final density
as the control point It is possible to have
dual 4-20 mA outputs from two-wire
loop-powered meters but as the main
4-20 mA output representing the prima-
ry variable is also HART then an external
HART Loop Converter or HART IO card in
the control system can provide second-
ary tertiary and quaternary variables as
4-20 mA signals A Coriolis meter is trulya multi-variable device Certain two-wire
devices are also available with Profibus
or Foundation Fieldbus communication
Cutting Wiring CostsIn 2003 WIBEXERA (International
Instrument Usersrsquo Associations) Report
T 2732 X 03 was published and it pro- vided an average survey of prices quoted
in projects at that time for the provision
of power supplies for four-wire instru-
ments The price ranged from euro1200
to euro1800 per instrument depending
upon design and plant characteristics
for an average cost of euro1500 (about
$2000) It would be reasonable to
assume an inflationary factor of 2 per-
cent per annum giving an approximate
current-day figure of $2500
From another source within thechemical industry an estimation of
$40foot to $50foot was given for in-
stallation of four-wire cabling For a
linear 50-foot cable run with for ex-
ample a 10-foot vertical at each end
this equates to $3150 Actual costs
and budget estimates have been given
as high as $10000
The Extent of the Opportunity The modern post-war flow measure-
ment technologies have different powerrequirements and consequently they
are not all available for the
same size range in two-wire
loop-power form For example
two-wire Coriolis flowmeters
are limited to 2rdquo diameter
electromagnetic and inline
low-pressure gas ultrasonics
are limited to 8rdquo and vortex
and inline liquid ultrasonic are
limited to 12rdquo
Nevertheless for thechemical industry in particu-
lar perhaps two-thirds of the
process pipes in a plant will be no larger
than 2rdquo and even when the host process
pipe is larger a correctly sized flowmeter
can still be less than 2rdquo There is consid-
erable scope for two-wire loop-power to
deliver value for flow measurement ap-
plications with total safety
The virtues of Coriolis technology
have been covered but what about
other two-wire technologies An elec-tromagnetic flowmeter in two-wire form
YSTEMS DESIGN | Flow Measurement
In todayrsquos volatile global mar-
ketplace return on investment
calculations for plant upgrade or
new plant construction projects
may go through several itera-
tions before the trigger is finally
pulled or indeed not pulled
ldquo
rdquo
COURTESYENDRESS+HAUSER
Figure 2 Two-wire Coriolis flowme- ters became available in 2011
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2245
can be used on water wastewater or
a light water-based slurry provided the
fluid has around a 20 microSeimenscenti-
metre (microScm) electrical conductivity
A magnetic flowmeter is full bore un-
less flowrates dictate a reduced meter
size in the interests of performance and
so there are no intrusions into the flow
stream and no pressure loss An accu-
racy of 05 percent of reading is normal
from a two-wire magnetic meter and a
modest five diameters (5D) of straight in-let run is needed to avoid error from up-
stream flow disturbances When the fluid
exhibits insufficient conductivity then
the same performance and installation
requirements can be met by an inline ul-
trasonic flowmeter provided the liquid is
essentially clean and bubble-free
For gas or steam applications a vor-
tex meter is the normal choice Using a
built-in temperature sensor a two-wire
loop-powered vortex meter can calculate
mass flow of saturated steam using in-ternal steam tables An external pressure
input allows mass flow of steam to be ac-
curately calculated even when saturated
steam becomes superheated as can oc-
cur downstream of a pressure regulating
valve With mass flow known the vortex
meter can calculate energy and heat flow
A new and exciting development is
the ability of the vortex meter to indicate
wet steam and calculate dryness frac-
tion or steam quality For safety and ef-
ficiency saturated steam should be dry
and free from condensate that is to say
it should possess a high steam quality
factor However the dry or wet state of
saturated steam can sit on a knife-edge
and shift to the opposing state due to
the slightest change in process condi-
tions Rapid and reliable indication of
this change of state is now available
Perhaps the most astonishingachievement in the power management
of two-wire loop-power flowmeters is
that of the ultrasonic biogas meter It is
now possible not only to measure the
flow of wet dirty variable composition
and low-pressure anaerobic digester
gas landfill gas and coal bed methane
gas with a two-wire loop-powered ultra-
sonic flowmeter but also the same de-
vice uses an inbuilt temperature sensor
in combination with measured sound
velocity to calculate methane contentcalorific value and energy flow
Technology to Take UsForwardModern flow technologies provide instru-
ment engineers with vital self-monitoring
information The format of such infor-
mation is easier to understand and act
upon when presented in accordance
with harmonized international guidelines
for online plant asset management eg
NAMUR Standard 107
Continuous plain-text self-diagnostic
and process-related information with
suggested remedies (Figure 3) make it
possible for instrument engineers andoperators to take action at the appro-
priate time mdash immediately or during
the next scheduled shutdown mdash saving
time and money by knowing the exact
health of their measuring point and the
probable actions required to rectify any
abnormal conditions Device verifica-
tion offering third-party validated trace-
ability can be performed on demand ei-
ther locally or remotely from the control
room without the expense of a man in
the field Calibration is then avoided ordeferred without process interruption
Where a process plant has a large
installed base of older mechanical tech-
nologies the decision to embark upon a
program of replacement for plant mod-
ernization cannot of course be taken
easily There are the stocks of spare
parts to consider along with the plant
instrument technicians who are trained
on and at ease with the old devices
However a process plant that retains
the older technology going forward willbe at risk and may find it increasingly
difficult or even impossible to maintain
a cost position that competes effective-
ly in the global market FC
wwwusendresscom
wwwflowcontrolnetworkcom January 2015 | 19
Steve Milford
is a Flow Product
Business Manager
for Endress+Hauser
Inc in Greenwood
Ind He has been
involved in flow
measurement since
1983 and has been
actively involved with standards devel-
opment for flow technology within the
International Standards Organization
(ISO) and the British Standards
Institute Mr Milford can be reached
at stevemilfordusendresscom
Steve Milford
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Coriolis Flowmeter | Magnetic Flowmeter | Two-Wire | Ultrasonic Flowmeter | Vortex Flowmeter
Figure 3 A modern instrumentrsquos display module can provide continuous plain- text self-diagnostic and process-related information
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2345
The bottom line is the volume of gas under one set of
pressure and temperature conditions is not the same as it
would be for the gas under different conditions Why is thisimportant Without compensation for compressibility read-
ings taken by gas flowmeters can result in measurementsmdash
and costs to the buyermdashsignificantly lower or higher than they
should be
The flow of gas in a system can be accounted for and
reported in a number of ways such as by volume by mass
flowrate and by energy Inline turbine meters can offer both
reliability and accuracy in measuring gas flow when matched
with a monitor capable of calculating and displaying results
that have been adjusted for the nature of the gas and impor-
tantly the pressure and temperature
Measuring Flow with an Inline TurbineFlowmeter
With an inline turbine meter gas flows into the meter through
a length of piping that helps to pre-condition the flow by
reducing undesirable swirls and asymmetry Where consid-
ered necessary a flow straightener may even be installed in
line to create a uniform flow profile to the extent possible
As can be seen in Figure 1 a rotor support within the tur-
bine housing further conditions the flow and directs it through
the blades of the rotor High-precision ball bearings allow the
rotor to freely rotate on the shaft
The rotorrsquos rotational speed is directly proportional to the velocity of the fluid passing through the meter The rotor itself
incorporates magnets (or magnetic blades depending on thedesign) while the housing is non-magnetic
A proximity sensor (also known as a pickup coil) is located
in line with the rotor and detects the electrical pulses gener-
ated by the ferrous rotor spinning through the magnetic field
Each pulse represents a discrete volume of gas The out-
put frequency provides the indication of the gas flow rate and
the accumulated pulses over a specified time represent the
total volume of fluid for that measurement period
Need for Calibration The flowrate of the gas through the meter cannot be deter-
mined accurately unless the meter is calibrated The fac-tory calibration determines the meterrsquos constant known
as a K-factor which is then inputted into the gas monitor
PPLICATION NOTES | Flow Measurement
20 | January 2015
Flow Control Magazine
COMPENSATING for
Compressibility inMeasuring Gas Flow Why K-factor adjustment is essential foraccurate inline turbine flow measurement
Unlike crude oil and other liquid fossilfuels natural gas poses a challenge
in monitoring the quantity of gas flowing
through pipelines While liquids do not com-
press gases do and the mass flowrate of
gas being transmitted through gathering
lines depends on both the pressure and
temperature
By Kevin Clark
Figure 1 Internal components of a liquid turbine flowmeter
C O U R T E S Y
T U R B I N E S
I N C
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2445
Wondering Whether the
Pump Guy Seminar
Is for YouCheck out the ldquoPump Guy Insightsrdquo
video series flwctrlcompginsights
PUMP GUY INSIGHT 1NPSHa vs NPSHrmdashWhy all pumps need gauges
PUMP GUY INSIGHT 3How to Operate Your Pump at Best Efficiency
PUMP GUY INSIGHT 5Head vs Flow
PUMP GUY INSIGHT 2 Your Pumps Are Constantly Moving On Their Curves
PUMP GUY INSIGHT 4 The Role of the Pump Reliability Chain
PUMP GUY INSIGHT 6How to Read a Pump Curve
PARTNER SPONSORSFor more information and to register
for upcoming Pump Guy Seminars
visit FlowControlNetworkcomPumpGuy
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2545
PPLICATION NOTES | Flow Measurement
22 | January 2015
Flow Control Magazine
Gas flowmeters measure the actual volume of gas passing
through the meter per minute irrespective of pressure and
temperature1
The volumetric flowrate of a gas is often corrected to
ldquostandardizedrdquo conditions of pressure and temperature While
ldquostandardrdquo conditions can vary depending on the definition
in the US this typically means a pressure of 1473 PSIA(pounds per square inch absolute) and a temperature of 60 F
The flowrate measurement is reported in standard cubic feet
per minute (SCFM)
Compensating for changes in pressure and temperature is
critical Consider a meter system setup for flowing conditions
of 60 PSIG (pounds per square inch gauge) and 60 F and the
line pressure decreases to 50 PSIG while the temperature
remains constant The difference in SCFM between the two
is more than 15 percent which would cost the buyer more
for the gas than it should As Table 1 demonstrates even a
small variation in pressure will result in a surprisingly high er-
ror percentage
Automation of the K-Factor The K-factor is established by an initial factory calibration In
the case of a non-compensated flow monitor any variations
in pressure and temperature will result in manual adjust-
ments needed to the K-factor In order to maintain accurate
flow measurement users must monitor pressure and temper-
ature and make corresponding adjustments to the K-factor To eliminate these manual adjustments some suppliers offer
a flow monitor that automatically adjusts for any changes in
pressure and temperature
These monitors provide accurate flow measurement regard-
less of changing environmental conditions in some cases sup-
porting applications with pressures as high as 15000 PSIG and
temperatures between -350 F to 350 F with a standard accura-
cy of +-1 percent over a flow range of 05 ACFM to 650 ACFM
Final NotesDuring the operation of a flowmeter system the ability to obtain
a readout mdash and to adjust for line pressure and temperaturechanges mdash is sometimes compromised by a lack of electric
power This issue is especially true along gas pipelines in remote
areas To overcome this limitation some manufacturers have
designed low-powered flow monitors which can operate for up
to on year on a single lithium D-cell battery
It is important for users to recognize the effects of the
compressibility of gas As such the quantity of a gas flow-
ing through a gas flowmeter depends on the pressure and
temperature In order to ensure accuracy any flowmetering
system must employ a means to correct for these effects
Otherwise the readout is certain to be in error and could be
unnecessarily costing money This is particularly crucial onwellhead production and in billing scenarios FC
wwwturbinesincorporatedcom
Notations1 The measurement factor in the US is known as the
ACFM actual cubic feet per minute (Metric units are typically
ACMH actual cubic meters per hour)
Table 1 Error induced by line pressure changes
Constant Temperature with Varying Pressure
Pressure Temperature PulsesSCF Error
50 60 2556027821 1546
51 60 2517123288 1370
52 60 2479385307 1199
53 60 2442762186 1034
54 60 240720524 873
55 60 237266858 717
56 60 2339108911 566
57 60 2306485356 418
58 60 2274759285 275
59 60 2243894166 136
60 60 2213855422 000
61 60 2184610304 132
62 60 2156127771 261
63 60 2128378378 386
64 60 210133418 508
65 60 2074968632 627
66 60 2049256506 743
67 60 2024173807 857
68 60 1999697703 967
69 60 1975806452 1075
70 60 1952479339 1181 Flow Measurement | K-Factor | Measurement
Accuracy | Turbine Flowmeter
Find related content flowcontrolnetworkcomhellipSearch on
FLOWSTREAM
Kevin Clark is senior develop-
ment engineer for Turbines Research
amp Development LLC Turbine RampD is a
subsidiary and the research and techni-
cal support arm of Turbines Inc which
serves a range of industries and applica-
tions from oil amp gas to cryogenic liquids
to custody transferKevin Clark
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2645
Pumps Bearings amp Seals TECHNOLOGY REPORT
FEATURES
SYSTEMS DESIGN
The ComplicatedCase of
Compressors
withSide-Streams
24 28 32BEST PRACTICES
How PumpingSystems
AffectSealing
Performance
TECH OUTLOOK
BearingSuppliers
Drive Gains InDeveloping
Markets
wwwflowcontrolnetworkcom January 2015 | 23
S P E C I AL S E C T I O N
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2745
The design and operation of compressors with side-
streams has always been difficult because flow entering the
compressor needs to be mixed with the core flow already
in the compressor (compressed in section-1) in a manner
that does not degrade the aerodynamic performance of sur-
rounding sections Minimizing losses and ensuring proper
mixing of the side-stream flow and core-flow are required to
ensure effective performance of a compressor of this sort
Key considerations for an application involving compres-
sors with side-stream flow include
The plant process typically dictates the side-stream
flange pressure
The impellers upstream of the side-stream should
achieve the necessary pressure for the core-flow
The side-stream flow is typically at a temperature dif-
ferent from compressor core-flow temperature
Process plants need some degree of operational flex-
ibility ie the ability to support variations in core-flow condi-
tions and side-stream conditions
Modern process plants are usually specifying more than
one operating conditions (sometimes two or more manda-
tory conditions) which can present challenges to compres-
sors with side-streams Adding to these issues modern
compressors should operate with much higher impeller tip
The COMPLICATED CASE ofCompressors with Side-StreamsConsidering key system design requirements
to ensure operational efficiency By Amin Almasi
4 January 2015
Flow Control Magazine
|
y
g
Some compressors in certain applications
have one or more incoming side-streams
(or side-loads) that introduce side-stream
flow to mix with the core flow In other words
a radial side-stream inlet is utilized in multi-
impeller centrifugal compressors to introduce
additional gas into the mid-stage of a com-
pressor This design enables optimization in
some process plants However the flow dis-
tribution after the junction of the side-stream
and the main return channel of the upstream
section can significantly affect the perfor-mance of the next section of compressor
In most cases the pressure levels at these
side-streams should be accurately predicted
to meet the theoretical performance
Compressor station at a natural gas processing plant
R U D M E R Z W E R V E R I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2845
speeds and inlet Mach numbers compared to previous
generations of compressor technology
Likewise side-streams are now com-
monly used with medium-sized and
large-sized compressors (eg 1ndash60
MW) The costs associated with cor-
rections on side-stream compres-
sor applicationsmdashany repair
inefficient operation and power
lossesmdashwould be very high Fur-
ther compressors with side-streams
are usually sensitive and difficult
machines to operate In particular
performance curves (performance
pressures efficiency etc) are sen-
sitive to suction inlet conditionsside-stream inlet conditions vol-
ume flow ratio (side-stream vol-
ume to core-flow volume) and side-stream losses
Compressors with side-stream often perform far below
expectations The main reason is that side-stream compres-
sors are different than conventional compressors (without
a side-stream) in design and operation For a compressor
with side-streams tighter tolerances in operating conditions
must be identified and applied Uncontrolled variations of
suction pressure or side-stream pressure are major prob-
lems Another major issue is the variations of the flow ratio
(side-stream flow to core-flow)
Compressor Side-Stream amp Mixing SectionIn many centrifugal compressors the portion of the side-
stream system from the flange connection to the mixing
section is similar to a compressor inlet A great challenge
is ensuring the mixing section provides circumferentially
uniform merged-flow with minimum losses This can be
achieved via effective design of the inlet configuration and
mixing section of the side-stream compressor such that
the impeller can be maintained over the whole operating
range of the compressor In many cases while there are
mixing sections provided for the machine the flows do not
completely mix before entering the impeller of the section-2
(the impeller after the mixing section) Non-uniformity at
inlet flow to the impeller is a key concern for compressor
performance
Another consideration is a compact design of the side-
stream mixing section Specifically a mixing section with
less axial length is always preferred This axial length can af-
fect the compressor rotor dynam-
ics the rotor length and over-
all compressor performance
(design cost operation and
reliability)
The side-stream exit pressure
(side-stream pressure at inlet
of the mixing section) is mainly
a function of the side-stream
flow velocity and the pres-
sure in the previous section of
the compressor Conversely the side-
stream flange pressure can depend on
side-stream flow velocity and section-1
exit conditions Therefore the side-stream
inlet flange volume flow is a function of theflange pressure compressibility (at that
pressure and temperature) and mass flow
Some engineers assume that the side-stream flange pres-
sure is equal to the inlet pressure of the first impeller of the
section-2 This is not true The mixed total pressure can be
estimated on a mass-averaged basis using side-stream total
pressure and return channel exit (section-1) total pressure
In some designs because of the lower static pressure at
the side-stream exit the total pressure at the return channel
exit is lower even though the velocity upstream is roughly
matched for both streams The pressure usually increased
at the returned channel but it can be reduced again at the
side-stream exit While simple in nature this can have an
impact on the prediction of pressure at the side-stream exit
and overall mixing section performance Based on basic flow
principles it was usually assumed that the static pressure
was equal between both flow streams at the mixing location
While this assumption might be used in rough calculations
the accurate simulations have shown this assumption is not
true In fact there are some points (for instance the shroud
wall at the exit of the return channel and the hub wall at
the exit of the side-stream) where this assumption is true
However this is not valid for all locations There are pressure
changes that occur from a side-stream flange to the inlet
of the next section (section-2) which depend on different
factors The first factor is the frictional losses due to side-
stream geometry from side-stream flange to plenum mix-
ing section etc The other factors are pressure changes due
to local curvature and geometry details of mixing section
Another consideration is the operation of a compressor
with side-stream at part-load The performance of the side-
wwwflowcontrolnetworkcom January 2015 25
Figure 1 An example of a centrifugalcompressor with side-stream
COURTESY SIEMENS
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 29456 January 2015
Flow Control Magazine
|
y
g
stream path the mixing section and
the downstream impellers when ma-
chine is operated at part-load or even
off-design operating flows will result
in additional compressor performance
problems In such a case both veloc-
ity profiles and pressure variations in
various parts (side-stream path mixing
section etc) will be different resulting
in complicated flow patterns and com-
plex aerodynamics behaviors
Side-Stream CompressorSectional Performance
Typically vendor-supplied compressor
performance curves reflect flange-to-flange performance because that is
what the plant engineers need to
evaluate the proper operation of their
system (for example from suction to
side-stream and from side-stream to
discharge) In many cases compres-
sor vendors also provide the over-
all compressor performance curves
and performance curves for section-1
(from suction to side-stream) and sec-
tion-2 (from side-stream to discharge)
Flange-to-flange data if not interpret-
ed properly can lead to false conclu-
sions about the relative performance
of individual sections of a compression
system For example if side-stream
losses from the flange to mixing sec-
tion are attributed to the downstream
section (section-2) it will cause the
downstream section (section-2) to
appear low in performance while the
upstream section (section-1) will show
high performance levels
An important behavior to con-
sider is when the actual side-stream
pressure is different than the rated
side-stream pressure When the side-
stream pressure is slightly higher than
the outlet pressure of the section-1
it (section-1) shows a relatively higher
performance compared to the real sec-
tion-1 performance In some cases
the performance of section-1 could be
considerably higher than section-2 In
other words when performance is de-
termined flange to flange the higher
flange pressure is seen as extra ldquopseu-
dordquo work done by the section (since this
is an inconsistent thermodynamic vol-
ume) resulting in a relatively high sec-
tional efficiency (section-1 shows a rel-
atively high efficiency) This is the case
for many compressors with side-stream
because the whole system is designed
(or specifically the side-stream location
is selected) in a way aimed at main-
taining the real side-stream pressure(side-stream inlet) above the section-1
outlet pressure because if the real side-
stream pressure becomes lower than
the section-1 outlet pressure the flow
may (theoretically) reverse
This is particularly important when
the side-stream mass flow is much
lower than the mass flow of core-flow
The above-mentioned reasons explain
why in many simulations calcula-
tions and performance reports related
to compressors with side-stream the
section-1 shows a relatively good ef-
ficiency and section-2 appears low in
efficiency
When the side-stream pressure is
slightly lower than the outlet pressure
of the section-1 the section-1 might
show a relatively lower performance
compared to section-2 This could oc-
cur in some recycle services where the
side-stream is actually a recycle flow
with a mass flow around two to five
times the core-flow The side-stream
(recycle) flow is returned from down-
stream of the compressor to be slightly
compressed and recycled to the down-
stream Such a recycled side-stream
compressor can present unique chal-
lenges for design and operation This
kind of machine usually needs very
special operating procedures and very
fine adjustments regarding operating
pressures and flows
Side-Stream Compressor
Performance amp Operation An important consideration is the sen-
sitivity of compressor overall perfor-
mance curve and sectional perfor-
mance curves to the flow ratio (ratio
of side-stream flow to core-flow) and
to the inlet conditions Variations in
the flow and pressure of the main
suction and side-stream inlet should
be controlled within tight tolerances
For compressors with side-stream the ASME PTC-10 code stipulates limits on
flow ratio (side-stream volume to core-
flow volume) The acceptable variation
in volume flow ratio in a compressor
with a side-stream is +-5 percent as
per ASME PTC code The requested
side-stream pressure tolerance is not
usually specified in compressor codes
but it should be around +- 2 percent
(or sometimes +- 25 percent)
Variance in flow ratio impacts the
velocity levels where the two streams
merge Significant variation in the ve-
locity profile upstream of the impeller
changes the incidence on the blade
leading edge of the following impel-
ler This change in incidence leads to a
change in sectional performance over-
all compressor performance and train
efficiency
If the flow ratio is varied between 95
percent and 105 percent (tolerances
specified in the ASME PTC-10 code)
the flange pressure changes accord-
ingly resulting in a change in the sec-
tional performance and overall perfor-
mance The sectional efficiency varies
sometimes more than +- 4 percent
This variance reduces as the flow is de-
creased toward surge However as the
flow is increased toward overload the
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3045wwwflowcontrolnetworkcom January 2015 27
variance increases up to higher values
(even in some cases three to five times
compared to variations near the surge
zone) For example in a case study
for a compressor with side-streams a
+- 5 percent variation in flow ratio and
associated changes (pressures losses
etc) the sectional efficiency reduced by
approximately 34 percent at the rated
flow at allowable operating points at
the end of curve (near the overload
ie choke) efficiency reduced by ap-
proximately 55 percent These results
show that the variation in sectional
performance and overall performance
due to flow ratio is highest at operat-ing points near the overload and low-
est at operating points near the surge
For compressors which work most of
the time at high flow (flow higher than
rated flow and discharge pressure low-
er than rated pressure) the effects of
flow ratio deviations (and subsequently
efficiency reduction) would be higher
than compressors working on the left-
hand side of curve (say with sufficient
margins near the surge)
In the compressor codes (such as
API 617) the compressor power varia-
tions should be maintained below 4
percent However in some applica-
tions clients require tighter tolerances
on the consumed power sometimes
below 2 percent (or even below 15
percent) Some studies suggest while
+- 5 percent of volume flow ratio is
suitable for performance test as per
ASME PTC-10 code some plants re-
quire tighter control on the consumed
power and compressor performance
(lower limits on the efficiency) the tol-
erances on the volume flow ratio could
be tighter than ASME PTC code In this
regard +- 4 percent tolerance can be
suggested on the volume flow ratio (ra-
tio of side-stream flow to core-flow) of
compressors with side-streams
Based on operational experiences
acceptable variations in volume flow
ratio and inlet pressures (suction inlet
and side-stream inlet) of a compressor
with side-streams are +- 4 percent
and +- 2 percent respectively
Another important consideration is
the required adjustments for the flow
ratio (side-stream flow to core-flow)
Compressors with side-stream usually
require fixed side-stream flange pres-
sures For a compressor with some variations in operation conditions (even
small changes) it is not usually pos-
sible to achieve optimum operation by
keeping the flow ratio (side-stream to
core-flow) constant The flow ratio has
to be adjusted according to the inlet
flow at which the machine is operating
in order to get the required correspond-
ing side-stream flange pressure
Thermal changes have also been
known to cause some instability in
centrifugal compressors An example is
the thermal-induced change of resid-
ual unbalance For compressors with
side-streams which feature tempera-
ture differences between core-flow and
side-stream flow the thermal behav-
ior of the compressor is usually more
complex and requires more attention
Heavy Gas ChallengeHeavy gases (such as heavy hydrocar-
bon gases eg propane propylene
MTBE (Methyl Tertiary Butyl Ether))
have very low gas sonic velocities that
produce high Mach numbers in the
aerodynamic flow paths For these
services because of high Mach num-
ber high flow coefficient stages have
very narrow flow maps characterized
by limited surge and choke margins
Compressors with side-streams in
these services present great challeng-
es This is to say the side-streams and
associated mixing further complicate
design operation and performance
prediction because the pressure tem-
perature and flow conditions at each
one of these side-streams as well
as at the exit of the machine require
stringent tolerances to optimize the
overall efficiency and performance
As such it is important to accuratelymodel design operate and moni-
tor performance characteristics of any
impellers diffusers return channels
and generally all flow-path components
in a compressor with side-stream FC
Amin Almasi
is a senior rotating
machine consultant
in Australia He is
a chartered profes- sional engineer of
Engineers Australia
(MIEAust CPEng ndash
Mechanical) and
IMechE (CEng MIMechE) holds
bachelorrsquos and masterrsquos degrees
in Mechanical Engineering and is
a registered professional engineer
in Queensland He specializes in
rotating machines including cen-
trifugal screw and reciprocating
compressors gas turbines steamturbines engines pumps subsea
offshore rotating machines LNG
units condition monitoring and reli-
ability Mr Almasi is an active mem-
ber of Engineers Australia IMechE
ASME and SPE He can be reached
at aminalmasiymailcom
Amin Almasi
Compressor | Gas Flow | Performance Curve | Side-Stream Flow
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3145
The pressure in the stuffing box
containing the packing can be estimat-
ed by the following equation
SBP = [Discharge ndash Suction] 3 + Suction
Pressure at the bottom of the stuff-
ing box will be higher than the suction
pressure but considerably lower than
the discharge pressure It should be
noted this calculation will yield a con-
servative estimate of stuffing box pres-
sure that can be further reduced by
pump design
A hole in the stuffing box serves as
a port for injecting clean fluid that cir-
culates around a lantern ring aligned
under the flush port The fluid flushes
solids back into the process to protect
the packing from abrasive wear If the
clean fluid is injected at a pressure ex-
ceeding that at the bottom of the stuff-
ing box some of it will leak back into
the process and some will leak out to
the atmosphere Recommended flush
injection pressure is 15ndash30 PSI (1ndash2
Bar) greater than the pressure at the
bottom of the stuffing box
Fluid injection is also used to lubri-
cate and cool dry-running packing that
is subject to frictional heat and to pre-
vent air from entering the pump which
reduces flow and operating efficiency
Centrifugal pumps utilize three
types of impellersmdashopen semi-open
and closed (Figures 2 3 amp 4) Open
designs prevent fluids with large solids
from clogging the impellers but at theexpense of pump efficiency Backing
plates on semi-open designs serve to
trap the fluid for more efficient opera-
tion Closed impellers are for use with
clean fluids since solids could ac-
cumulate in the eye which would re-
quire tearing down the pump to remove
them
Single-Stage CentrifugalPumpsSingle-stage centrifugal pumps typi-
cally have good bearing support of the
shaft with few run-out or ldquowhiprdquo prob-
lems However in some cases they
are subject to cavitation This occurs
in the eye of the impeller where the
fluid is under vacuum If the pressure
is low enough it will cause the material
to vaporize forming air or water vapor
bubbles As the fluid passes through
How Pumping Systems Design Affects Sealing Performance
By Chris Boss
8 January 2015
Flow Control Magazine
|
Understanding how different types of pump designs impact
sealing is critical to optimizing efficiency safety and lon-
gevity of the sealing system Used for a wide variety of media
including clear fluids solutions and slurries single-stage
centrifugal pumps are one of the most common
types (Figure 1) Fluid drawn into these pumps
enters the eye of an impeller that spins itto the outside of its container
or volute building pressure as
it moves toward discharge
Some of this fluid will work
its way behind the impeller
where it must be sealed with
compression packing or a
mechanical seal
Figure 1
Figure 2 Figure 3 Figure 4
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3245
the pump under increasing pressure
these bubbles implode sending shock
and vibration through the impeller
adversely affecting the seal This phe-
nomenon can be mitigated by running
the pump at slower speed and higher
pressure at the suction end to prevent
air from entering the fluid
Double-Ended Split-CasePumpsOperating on the same centrifugal prin-
ciple but slightly different geometry are
double-ended split-case pumps (Figure
5) Fluid enters both ends of the pump
and is directed into the eye of an impel-ler which spins it out of the volute to
discharge Packing is installed on both
the shaft and bearing ends so the stuff-
ing box is exposed only to suction pres-
sure which is usually quite low
Axial Flow Pumps Axial flow pumps operate like hydro
turbines in reverse whereby a propeller
(or axial impeller) pushes the fluid to
discharge (Figure 6)
Since the stuffing box is located
downstream of the propeller at the dis-
charge end of the pump the packing is
exposed to the full discharge pressure
Vertical PumpsVertical turbine pumps are typically
flange-mounted on a floor extending
downward into a water-filled sump
hole (Figure 7) Available as single- or
multi-stage pumps they feature an
impeller or series of impellers rotated
simultaneously by a single shaft The
impellers increase the pressure of the
upward flow subjecting the stuffing box
to full discharge pressure
Vertical pumps can be quite long so
inadequate bearing support can cause
the shaft to run out This can induce
undesirable lateral motion on the pack-
ing Worse the packing may be forced
to serve both as a bearing and a seal To
withstand these conditions the packing
should be resilient elastic and resistant
to deformation These properties rule
out packing such as graphite foil in favor
of fiber-based materials
Multi-Stage PumpsMulti-stage pumps are used for high-
pressure applications such as feeding
the boilers in steam-powered generating
plants Stuffing box pressure can vary
with pump design and number of stag-
es Designed for clean fluids and high
operating speeds these pumps typically
have high- and low-pressure ends with ahydraulic pressure equalization line run-
ning between the stuffing boxes
Like vertical pumps multi-stage
pumps feature a series of impellers to
build fluid discharge pressure In the
case of the six-stage pump pictured in
Figure 8 fluid enters at the drive end
where a stuffing box is exposed to suc-
tion pressure Channeled from one
impeller to the next through the pump
casting the fluid can reach extremely
high pressures at discharge
A second stuffing box located at the
bearing end is exposed to an intermedi-
ate pressure from the third impeller This
pressure is greater than the suction pres-
sure but much less than the discharge
pressure which can reach 2000 PSI
Fortunately the stuffing boxes in
these pumps are not exposed to dis-
charge pressures and typically see be-
low 500 PSI which is within the range
of some packing materials
wwwflowcontrolnetworkcom January 2015 29
Figure 5
Figure 6
Figure 7
Figure 8
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 33450 January 2015
Flow Control Magazine
| Gear PumpsPositive-displacement or gear pumps
operate on a different principle than
centrifugal pumps In external gear
pumps the fluid flows around the out-
side of the gears the intermeshing
of which forces it through the pump
to discharge (Figure 9) This design
makes these pumps particularly suit-
able for use with highly viscous fluids
such as resins emulsions syrups and
adhesives As such they are used for
transfer or metering applications
It should be noted gear pumps will
continue to displace fluid as long as
their shafts are turning which can pose
a problem if a clog occurs at the dis-
charge The resulting buildup of pres-
sure can blow out seals and damage
the pump Therefore most gear pumps
have pressure relief valves to divert
fluid back to the suction side for re-
circulation through the pump Internal
gear pumps operate slightly differently
but also have pressure relief valves to
prevent damage from excessive pres-
sure (Figure 10) In both external and
internal gear pumps the maximum
stuffing box pressure is determined by
these valves
Other rotating equipment includes
mixersagitators which are similar to
pumps in terms of the speeds to which
the packing is exposed There are ba-
sically three types of mixersagitators
top- bottom- and side-entry Top-entry
models are subject to the same con-
cerns about shaft run-out ldquowhiprdquo and
lateral forces on the paddles that are
encountered in some vertical pumps
Although some fluid may splash onto
the packing these mixers basically run
dry so the packing must have the abil-
ity to dissipate the resulting frictional
heat
In bottom-entry mixers the packing
is always exposed to fluid and may also
be exposed to solids requiring abra-
sion-resistance If the seal fails the en-
tire contents of the tank will eventually
drain out onto the bearings the floor
and other components under the stuff-
ing box
The packing in side-entry mixers may
be fully or intermittently exposed to flu-
id as well as side loading and vibration
Aside from media temperature
speed and other application variables
the configurations and operating prin-
ciples of rotary-type pumps exert differ-
ent forces on the seals used to keep
them from leaking These forces can
spell the difference between accept-
able seal performance and failure
Understanding these differences has
important implications that should be
taken into account to assure proper
sealing selection for long-term trou-
ble-free performance FC
wwwgarlockcom
Chris Boss is
a senior applica-
tions engineer for
Garlock Sealing
Technologies in
Palmyra NY He
has held various
positions in produc-
tion engineering
product development and applica-
tions engineering for the companyrsquos
compression packing division He
is a BSME graduate of the State
University of New York at Buffalo Mr
Boss can be reached at 800 448-
6688 or chrisbossgarlockcom
Chris Boss
Cavitation | Centrifugal Pump | Pump Packing | Sealing System
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Figure 9
Figure 10
Aside from media temperature speed and
other application variables the configurations
and operating principles of rotary-type
pumps exert different forces on the seals used
to keep them from leaking These forces can
spell the difference between acceptable seal
performance and failure
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3445
NS IDERNDUSTRIAL AUTOMATION + PROCESS CONTROL
WANT
INFORMATION
ON THE
automationindustry
SUBSCRIBE NOW at wwwiainsidercouk
Published by Spitzer and Boyes LLC Write in 15 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
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Frost says the push from developing
economies is important as the market
is technologically mature and seeing
restricted growth in developed econo-
mies This is particularly true in Europe
and North America where recent finan-
cial insta-
bility has
reduced capital expenditure across end-
user industries
Bill Moore senior vice president of
sales development and channel man-
agement for global bearings manufac-
turer SKF says ldquosmartrdquo products and
the expansion of robust reliability pro-
grams are helping to drive new invest-
ment particularly in developed coun-
tries where the cost to compete is
high Frost says the magnitude of
the existing global installed base will
strengthen the need for replacement
and upgrades adding to market de-
mand as well
Frost says despite the potential
in developing economies the focus
on price as a product differentiator
may lead to intense price pressures
among manufacturers and bring down
the value of the overall market in the
short term The growing trend among
consumers to choose low-cost Chinese
imports will complicate this challenge
As price and quality become stan-
dardized across the globe customers
will base more of their purchasing deci-
sions on value-added services accord-
ing to Frost This will push manufactur-
ers to create more maintenance-free
solutions such as lubrication-free
bearings that offer end-users savings
on service and replacement costs and
reduce downtimeldquoOffering a complete line of prod-
ucts with comprehensive services will
be another feather in the cap of ven-
dors looking to widen their consumer
baserdquo notes Frost Industrial Automa-
tion and Process Control Research
Analyst Guru Mahesh
Moore says the trend of outsourcing
manufacturing to regions where labor
and production costs are favorable is
becoming less of a factor
ldquoThe days when cheap labor made
a significant difference in where a prod-
uct is manufactured mdash particularly high
value-added products or high weight
and bulk products mdash are coming to
an end as the cost of transportation
storage and inventory balance out the
benefits of production costs where la-
bor is a smaller percentage of the cost
of manufacturingrdquo Moore says ldquoLocal
manufacturing development will indeed
come to developing countries as their
ability to create markets that generate
economies of scale that support local
production is a clear trend and one that
all manufacturers will pay attention tordquo
Moore says that development of
maintenance-free or predictive tech-
nologies and products will be a sig-
nificant advantage to everyone in the
Bearing amp Coupling Manufacturers Focus
onDEVELOPING Economies
amp EFFICIENCY InnovationBy Amy W Richardson
2 January 2015
Flow Control Magazine
|
gy
Anew study from Frost amp Sullivan (wwwfrostcom) fore-
casts steady growth for the overall bearings and couplings
market based on rapid industrial development in high-growth
regions Specifically Frost predicts development in Mexico
Indonesia Nigeria Turkey Brazil Russia India and Chinawill help boost the bearings amp couplings market from $2206
billion in 2013 to an estimated $2676 billion in 2018
The development of maintenance-freeor predictive technologies will helpboost growth in the bearings market For example SKF is developing products that will automatically notifyusers when a bearing or mechanicalrotating component is approachingthe end of its useful life Pictured hereis an SKF Microlog analyzer a por- table condition monitoring tool
COURTESY SKF
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
improved productivity through simplified solutions The powerful technology and tools ensure repeatable
reliable accurate measurements Easier access to process data allows for better troubleshooting process
optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
For daily product notes visit the lsquoFeatured Productsrsquo section flowcontrolnetworkcom
ON THE WEB
1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3845
FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
and benefits as well as grids of
instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
services provided for the
mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
Brought to you by Beamex
Your Source For Fluid Handling Videos
Go towwwflowcontrolnetworkcomfreeinfo
Select appropriate issue ofFlow Control Magazine
Select advertisements thatinterest you
Enter your email amp clickldquoSubmit Requestrdquo
1
2
3
4
PRODUCT
INFORMATION
ONLINE
Follow these 4 steps to receive freeproduct information from suppliers
FREE
FEATURED VIDEO How to Calibrate aPressure Measurement Loop
For more information about FlowTube
sponsor packs email FlowControlGrandViewMediacom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4245
THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
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One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
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![Page 4: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/4.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 445
Do you need flow measurement with online density compensation
Available now with OPTISWIRL 4200 from KROHNE
Featuring integrated pressure and temperature sensors the new OPTISWIRL 4200
vortex flowmeter provides online density compensation for all types of gas and steam
The OPTISWIRL 4200 even masters fluctuating operating conditions with effortless
precision and helps to significantly reduce installation costs Itrsquos the smart choice for
auxiliary and supply processes in a broad range of applications
Developed for use in continuous volume flow measurements in safety-related
applications the OPTISWIRL 4200 is in full compliance with the IEC 61508 SIL2 safety
standard Units can be easily switched from non-SIL mode to SIL mode without the need
to call out a service technician
Minimising downtime is critical for your business Thatrsquos why the OPTISWIRL 4200
provides redundant data storage of all calibration and configuration data in the display
memory and the electronics module ndash transferring data to replacement modules is a snap
When efficiency and flexibility matter most the OPTISWIRL 4200 is the definitive choice
KROHNE ndash Flow measurement is our world
Please see our website for more information
The All-in-OneSolution
Write in 2 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 545
featurescontents
16 The Two-Wire Advantage
By Steve Milford Advances in two-wire instrumentation specifically in relation to flow-
meters have enabled significant cost benefits for new technology in-
stallations in terms of capital investment and cost of ownership
20 Compensating for CompressibilityIn Gas Flow MeasurementBy Kevin Clark
K-factor adjustment is a key factor in ensuring accurate gas flow mea-
surement for inline turbine meters The K-factor is established by an
initial factory calibration In the case of a non-compensated flow moni-
tor any variations in pressure and temperature will require manual
adjustments to the K-factor
2 | January 2015 Flow Control Magazine
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 qualied subscribers Non-qualied subscrip-
tion rates in the US 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 t he Circulation
Manager for more wire transfer information Single copies $10
per issue in the US and Canada Single copies $15 per is-
sue in all other countries All subscription payments are due in
US funds
POSTMASTER Send address changes to Flow Control PO BOX
2174 Skokie IL 60076-7874 Periodical postage rates paid at
Subscription Information Toll Free 8667214807Outside US 8477631867Mail PO Box 2174Skokie IL 60076-7874E-mail flowcontrolhalldatacom
SubscribeRenewChange of Addresswwwflowcontrolnetworkcomsubscribe
Birmingham AL 35242 and additional mailing ofces
copy Entire contents copyright 2015 No portion of this publica-
tion may be reproduced in any form without written permis-
sion of the publisher Views expressed by the bylined con-
tributors should not be construed as reecting the opinion
of this publication Publication of productservice information
should not be deemed as a recommendation by the publisher
Editorial contributions are accepted from the uid handling
industry Contact the editor for details Productservice infor-
mation 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
1 616
Pumps Bearings amp Seals Technology Report SPECIAL SECTION PAGE 23
24 The Complicated Case of Compressors
with Side-StreamsBy Amin Almasi
28 How Pumping Systems Design AffectsSealing PerformanceBy Chris Boss
32
Bearings amp Couplings Suppliers Position
to Drive Market GrowthBy Amy W Richardson
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 645
Do you know whatrsquos
gone out the window
at your facility
Magnetrolreg energy management solutions monitor and measure the energyflowing through your facility to reduce utility costs and make processes moreefficient Easy to install and operate TA2 thermal flow meters provide you withan efficient environmentally responsible way to manage compressed air andnatural gas cost centers
Make MAGNETROL Thermatel reg TA2 mass flowmeters part of your energy management strategyVisit magnetrolcomthermalmassflow or contact
your MAGNETROL representative for more information
Measure and control your compressed
air and natural gas energy costs with
Thermatelreg TA2
991266 PDJQHWUROFRP Write in 3 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 745
1 9 9 5 - 2 0 1
51 9 9 5 - 2 0 1
5
20th20th january 2015 | Vol XXI No 1
4 | January 2015
Flow Control Magazine
departmentscolumns6 EDITORrsquoS FILE
4 flow things you need to know aboutthis month
14 APPLICATIONS CORNERa coriolis mass flowmeter providesa better solution
39 WORD SEARCH temperature measurement
40 QUIZ CORNER how to calculate orifice plate flow rate
Cover imagesFlowmetercourtesyEndress+HauserBackgroundiStock
8 NEWS amp NOTES api 624 valveemissions update intelligent features toboost desal pumps market hydraulic fractur-ing water treatment on the rise
34 UP CLOSE with Micro Motionrsquos Model5700 Coriolis Transmitter
35 NEW PRODUCTS
36 WEB RESOURCE FILE
38 ADPRODUCT INDEX
S I N C E 1 9 5 8
Itrsquos More than a Check Valve
Itrsquos a Check-All
When You Need Absolute Precision
CHECK-ALL IS THE ONLY CHOICE
Our spring loaded check valves are assembled
to your exact needs ensuring absolute precision
and reliability They work like they should Plus
most lead times are less than one week Thatrsquos
what makes Check-All the only choice
Get me a Check-AllManufactured in
West Des Moines Iowa USA515-224-2301 bull salescheckallcom bull wwwcheckallcom
Write in 4 or Request Info Ins tantly at wwwFlowControlNetworkcomfreeinfo Write in 5 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
Return on investment calculations for plant upgrade or new
plant construction projects may go through several iterationsbefore the trigger is finally pulled or indeed not pulledldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 845
The new Ultratrade 8c The capability and performance
your market demands
Copyright copy FMC Technologies Inc All Rights Reserved
FMC Technologiesrsquo Ultra 8c ultrasonic owmeter shares the advanced technology
of the next generation Smith Meterreg Ultra Series meters With its touchscreen
interface upgradable memory and high-speed processor the Ultra 8c provides
cutting-edge performance and diagnostic ability And with additional measurement
paths the Ultra 8c has even better cross-ow and swirl compensation for improved
accuracy and repeatability Whether for leak detection or custody transfer theUltra 8c gives you the assurance of superior performance in the eld even for the
most viscous crude oils in todayrsquos market
For more information visit wwwfmctechnologiescomultrafc
wwwfmctechnologiescom
Write in 6 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 945
20 Years of Flow Control This
year marks the 20th Anniversary of
Flow Control magazine Launched
in 1995 with the aim of serving technical
professionals involved with designing oper-
ating and maintaining fluid handling systems in a wide range of
industries Flow Control has leveraged its many years of experi-
ence to establish a unique niche and reputation for providinghigh-quality information to you our subscribers I congratulate everybody who helped
Flow Control get to where it stands today Herersquos to another 20 years of success
Training Time Itrsquos a new year and we have two new
training opportunities for
you to enhance your skillset in 2015
Regular Flow Control columnists Da-
vid W Spitzer and Larry Bachus will
be presenting three-day courses on
Flow Measurement and Pumping
Systems respectively I encourage you and your colleagues to take ad-
vantage of these important training
opportunities For more details see
flwctrlcomflowseminar amp
flwctrlcompumpguy
Oil amp Gas Gender Gap Results of a
new global workforce survey conduct-
ed by OilCareerscom and Air Energi
show a gender gap in the oil amp gas industry
persists despite ongoing efforts to recruit more
women into the industry According to hiring
managers the
top three factors
that significantlycontributed to
the gender gap
in the oil amp gas
industry are
1 A lack of women entering the industry (55
percent)
2 An industry culture created by a male-domi-nated environment (53 percent)
3 The logistics requirement ie travel shift
and working patterns in the field (30 percent)
For more on this story and an infographic seeflwctrlcomog_gendergap
Rockwell Automation Fair 2014 Our colleagueKevin Parker at Processing magazine attended the
annual Rockwell Automation Fair Nov 9-10 in
Anaheim Calif Parker gleaned some interesting perspec-
tive on key trends in process automation including
1 Hardware and software are more blended than ever
2 Fog computing (a kind of cloud computing) is making
headway in industrial engineering environments where latency is a critical concern
For Parkerrsquos full report from the Automation Fair see flwctrlcomrockwellfair2014
DITORrsquoS FILE
6 | January 2015
Flow Control Magazine
4 Flow Things You Need to Know
GROUP PUBLISHERPROCESSINGFLOW CONTROL
MICHAEL C CHRISTIAN | (908) 507-5472mikecgrandviewmediacom
NATIONAL ACCOUNTS MANAGERJIM SEMPLE | (908) 963-3008 jsemplegrandviewmediacom
EXECUTIVE DIRECTOR OF CONTENTMATT MIGLIORE | (610) 828-1711
mattgrandviewmediacom
MANAGING EDITOR AMY W RICHARDSON | (205) 408-5050
arichardsongrandviewmediacom
COLUMNISTS
LARRY BACHUSDAVID W SPITZER JESSE YODER
ART DIRECTORJULIE FLYNN
juliegrandviewmediacom
MANAGER - DIGITAL OPERATIONSMARY BETH ROMANO
SUBSCRIPTION amp REPRINT REQUESTSflowcontrolhalldatacom
Administrative TeamGENERAL MANAGER
BARRY LOVETTE
CHIEF OPERATIONS OFFICERBRENT KIZZIRE
VICE PRESIDENT OF FINANCEBRAD YOUNGBLOOD
VICE PRESSIDENT OF B2B GROUPMIKE WASSON
CHIEF REVENUE OFFICERCHRIS DOLAN
VP AUDIENCE DEVELOPMENTDELICIA POOLE
AUDIENCE DEVELOPMENT MANAGER ANNA HICKS
DIGITAL AUDIENCEDEVELOPMENT ANALYST
STACY BARNES
EDITORIAL ADVISORY BOARDLarry Bachus Bachus Company IncGary Cornell Blacoh Fluid Control
Jeff Jennings Equilibar LLCMitch Johnson JMS SoutheastPeter Kucmas Elster Instromet
Jim Lauria Water Technology Executive
John Merrill PE EagleBurgmann IndustriesSteve Milford Endress+Hauser US Tom OrsquoBanion Emerson Process
Management Micro MotionDavid W Spitzer PE Spitzer and Boyes LLC
Tom Tschanz McIlvaine Company John C Tverberg Metals and Materials
Consulting EngineersJesse Yoder PhD Flow Research Inc
WINNER
WINNER WINNER
PERSPECTIVES FROM THE MONTH THAT WAS IN THE WORLD OF FLOW CONTROL
WINNER WINNER
THE
NETWORK
1
2 3
4
1 9 9 5 - 2 0
1 51 9 9 5
- 2 0 1 5
20th20th
Matt Migliore Executive Director of Content MattGrandViewMediacom
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1045
Endress+Hauser Inc
2350 Endress Place
Greenwood IN 46143
infousendresscom
ww wusendresscom
Sales 888-ENDRESS
Service 800-642-8737
Fax 317-535-8498
Guided wave radar level products - built for safety precision and efficiency
bull Reliable non-contact measurement even for changing process conditions
bull HistoROMreg data management - concept for fast and easy
commissioning maintenance and diagnostics
bull Multi-Echo Tracking evaluation - highest reliability even with the
presence of obstructions in the vessel
bull Hardware and software developed according to IEC61508 up to SIL3(in homogeneous redundancy)
bull Seamless integration into control or asset management systems
bull Worldrsquos easiest proof test concept for SIL saves time and cost
wwwusendresscommicropilot-radar-level
The newest generation of Micropilot
Taking your process to the next level
Write in 7 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1145
HE OUTLOOK | News amp Notes
1 ISO15848 ldquoMeasurement test and qualification proce-
dures for fugitive emissionsrdquo
a Part I ndash ldquoClassification system and qualification proce-dures for type testing of valvesrdquo
b Part II ndash ldquoProduction acceptance test of valvesrdquo
2 API 622 ldquoType Testing of Process Valve Packing for Fugitive
Emissionsrdquo
3 End-user defined fugitive emission reduction requirements
Key aspects of valve testing per API 624 include
The standard covers rising and rising-rotating stem
valves up to 24rdquo diameter
Class 1500 valves are not covered
The test medium is methane
310 test cycles are required with three thermal cycles Temperature application range is from -29 C to 538 C
with last cycle 10 cycles user-defined (can be -45 C)
Re-tightening of gland bolts is not permitted during test
Valve stem test orientation is vertical
Several valves must be tested to achieve API 624 com-
pliance Similar industry principles applied to test valves
qualify two nominal sizes smaller one size larger and one
pressure class below
Allowable leakage is 100 PPM maximum
Gate and globe valves need to be tested separately
For example Gate Valves per API602 four tests API600
eight tests (up to 20rdquo diameter) API 603 eight tests andfor Globe Valves per API 602 four tests
Test valves should be production valves not specially
manufactured test valves
As a result of the release of API 624 testing companies have
been gearing up for an increase in the number and size of
test valves and new test houses are coming to market Withthis in mind implementation of API 624 needs to be carefully
monitored and claims from valve manufacturers should be
validated by requesting to view test results Important factors
to be mindful of include
Number of cycles on some valves could be detrimental
to packing as certain smaller size valves donrsquot come with
grease ports to keep the stem lubricated all of the time
Test failures of valve stem threads yokes and glands
Grease traps into packing and causes leakage
At higher temperatures a few greases create volatile
organic compound and burn off
Testing in vertical generates more heat in yoke area
Certain challenges need a good testing company that has
experience in testing on fugitive emissions and provides
guidelines to manufacturers in terms of use of packing valve
grease testing requirements etc
A preliminary survey was conducted with end-users regard-
ing current utilization and application of API 624 For a sum-
mary of responses from this survey visit flwctrlcom1oWijWz
Gobind Khiani PEng is with Fluor Canada Ltd Khiani has
spent 20-plus years in the energy and power business and 10-
plus years in the Western Canadian oil and gas industry Hecan be reached at 403 850-6982 or gobindkhianifluorcom
Valve Standards UpdateEnd-users ramp up compliance efforts for API 624
as new specifications emerge on the horizon
8 | January 2015
Flow Control Magazine
By Gobind Khiani
In the May 2014 issue of Flow Control (page
16) the new standard API 624 ldquoType Testing
of Rising Stem Valves Equipped with Graphite
Packing for Fugitive Emissions First Editionrdquo was
addressed This standard which was published
and put into effect in February 2014 estab-
lishes guidelines for testing industrial valves for
emissions compliance Since the publication ofthe May article further requests from industry
have spurred the creation of another specifi-
cation API 641 ldquoType Testing of Quarter-Turn
Valvesrdquo and an API ldquoPiping and Valvesrdquo commit-
tee has been formed Regulators and end-users
are also working on
1992 1998 2003 2008 2013 2020
4
35
3
25
2
15
1
05
0
M i l l i o n o f
t o n n e s y e a r Will API 624
have a stepeffect in reducing
fugitiveemissions
Global valve fugitive emissions
End User response at best
End User response actual
S O U R C E G O B I N D K
H I A N I
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1245
Intelligent Features to Boost Global WaterDesalination Pumps Market
The Global Water Desalination
Pumps Market is expected to grow
at a CAGR of 77 percent from 2015 to
2019 according to a new report from
TechNavio (wwwtechnaviocom)
The report shows demand for water
treatment has increased significantly in
developing countries where fresh wa-
ter resources can be scarce Providing
clean and potable water to huge popu-
lations has become a priority which is
pushing the demand for water desalina-tion pumps in the market according to
TechNavio
The report emphasizes the emer-
gence of intelligent pump systems as
a major driver of market growth In-
telligent pumps possess the ability to
regulate flow and pressure and these
systems can automatically adjust to
process and pump system changes
ldquoIntelligent pump systems are be-
ing adopted by many manufacturers
because of the high level of fault toler-
ance ability which leads to a significant
reduction in the total cost of owner-
shiprdquo said Faisal Ghaus vice president
of TechNavio in a news release ldquoThe
adoption of these systems will also
help industries comply with current Eu-
ropean Union regulations in relation toreduction in energy consumptionrdquo
The growing demand for clean wa-
ter worldwide will continue to augment
the demand for water desalination sys-
tems which will propel the Global Water
Desalination Pumps Market during the
forecast period
trendlines
wwwflowcontrolnetworkcom January 2015 | 9
Write in 8 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
Intelligent pump sys-tems are being adopt-
ed by many manufac-
turers because of the
high level of fault tol-
erance ability which
leads to a significant
reduction in the total
cost of ownership
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1345
HE OUTLOOK | News amp Notes
10 | January 2015
Flow Control Magazine
Hydraulic Fracturing WaterTreatment amp Reuse Expected to Soar
Wastewater treatment spending for
hydraulic fracturing is expected to
grow almost three-fold from $138 mil-
lion in 2014 to $357 million in 2020 in
the US according to a new report from
Bluefield Research
The US hydraulic fracturing industry
consumes over 1 billion barrels of wa-
ter annually producing 450ndash500 mil-
lion barrels of contaminated water for
disposal with only about 14 percent
treated and reused Bluefield cites watersupplies increasingly at risk tighter regu-
lations emerging in key states and costs
of disposal on the rise as factors con-
tributing to the substantial rise in water
treatment and reuse which is expected
to account for 27 percent of total pro-
duced and flowback water by 2020
Overall the US hydraulic fracturing
industry will spend $638 billion in 2014
on water management Water transport
and disposal costs will account for 66
percent of the total water managementspent this year with treatment compris-
ing roughly 2 percent
Bluefield reports water scarcity in
Western US states has had little im-
pact to date on fracturing water supply
but that is likely to change if droughts
persist Meanwhile state regulators are
beginning to tighten control of produced
water disposal In Pennsylvania where
policymakers in 2010 placed discharge
limits on wastewater from unconven-
tional oil amp gas operations statewide
treatment and reuse rates for the Mar-
cellus jumped to 90 percent in 2014
The increasing cost of transport and
injecting water into wells mdash now ac-
counting for 66 percent of water servicesspending mdash and the improving cost
structures of treatment provide another
driver of reuse Bluefield reports Well
operators that employ treatment and re-
use solutions spend on average $880
per barrel of water used compared to
$1020 per barrel of water trucked and
injected into wells although cost com-
parisons are site specific
ldquoFracking has been the Wild West for
the US water industryrdquo said Reese Tis-
dale president of Bluefield Research ina prepared statement ldquoThere are three
reasons for this first there has been
an explosive build-out of fracking well
installations now surpassing 126000
Second there has been a lack of clear
regulation on water management in key
markets And third there is not a one-
size-fits-all treatment solution for frack-
ing meaning solutions providers have
had to ascend a steep learning curve
to treat the variable wastewaters that a
single well is capable of producingrdquo
Tisdale notes that these inhibitors
while still acute are beginning to take on
a new form This is partially due to signifi-
cant gains in water management experi-
ence realized adoption of more efficientwater management strategies among
well operators and the emergence of
new policy mechanisms from regulators
that are playing catch-up with the fast-
moving hydraulic fracturing industry
trendlines
Treatment2
Disposal
6
Supply10
Storage22
Transport60
US $638Billion
S O U R C E B L U E F I E L D R
E S E A R C H
Write in 23 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
Industry-Leading
Warranties
Temperature Measurement Solutions
bull Probe type industrial RTDsbull Electronic temperature switchtransmitter bull Vapor-actuated remote thermometersbull Digital temperature indicatorsbull Platinum resistance temperature transmitterbull Compact OEM temperature transmitter bull Industrial amp instrument type bimetal thermometersbull Thermowells
1010 West Bagley Road I Berea Ohio 44017 I P 4402430888 I F 4402433472wwwnoshokcom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1445
New Technique Could ReduceEnergy Required for Oil Refinement
UK scientists have developed a
technique they say has the poten-
tial to dramatically reduce the amount
of energy required for the refinement
of crude oil
Professor Martin Schroumlder and Dr
Sihai Yang from The University of Not-
tingham (wwwnottinghamacuk ) have
led a multi-disciplinary team of scien-
tists from Nottingham the Science and
Technology Facilities Councilrsquos (STFC)
ISIS Neutron Facility Oak Ridge Na-tional Laboratory and Diamond Light
Source to discover a porous material
that works like a chemical sponge to
separate a number of important gases
from mixtures generated during crude
oil refinement
According to a news release from
The University of Nottingham the ex-
isting industrial process uses ldquohuge
amounts of energy to separate and pu-
rify these gases so the new technique
has the potential to revolutionize the oil
industry by significantly reducing car-
bon emissions and making the process
more environmentally friendlyrdquo
Commercially UsefulCrude oil is a raw material that is
refined to produce fuel for cars toheat homes and to create polymers
and other useful materials It is made
up of a complex mixture of hydro-
carbons (chemical compounds that
contain only hydrogen and carbon) of
which certain components are espe-
cially commercially useful
One industrial process used to
achieve hydrocarbon separation is
called ldquocryogenic distillationrdquo which is
widely used worldwide and uses vast
amounts of energy to generate the high
pressures and cryogenic temperatures
required to ensure efficient separation
research amp development
wwwflowcontrolnetworkcom January 2015 | 11
PLASTIC CONTROL VALVES FORALL YOUR CORROSIVE APPLICATIONS
PO Box 938 bull Angleton TX 77516Tel (979) 849-8266 bull wwwcollinsinstcom
Collins plastic control valves are
highly responsive control valves
designed for use with corrosive
media andor corrosive atmos-
pheres
Collins valves feature all-plastic
construction with bodies in PVDF
PP PVC and Halar in various body
styles from 12 - 2 with Globe
Angle or Corner configurations and
many trim sizes and materials
Valves may be furnished without
positioner for ON-OFF applications
Call for more information on our
plastic control valves
Write in 9 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1545
of hydrocarbon mixtures into pure components
However researchers say an innovative solution may
have come in the form of a novel chemical sponge This
porous material a metal-organic framework was devel-
oped by the same team at Nottingham just two years ago
Now in research published in Nature Chemistry for the
first time scientists have proven that it can be used toseparate hydrocarbon mixtures without the need for high
process pressures or very low process temperatures
Reusable MaterialsMade from cheap organic materials aluminum nitrate
salt and water the porous material called NOTT-300 is
able to adsorb different gases found in mixtures of hydro-
carbons at different rates making it possible to sepa-
rate them and extract the most useful ones NOTT-300
requires less energy to function than existing methods
as it operates at ambient temperatures and normal pres-
sures researchers say The gases that are adsorbed intoNOTT-300 can be removed without a significant energy
input and therefore the material can be easily reused
The team of scientists from Nottingham used Diamond
the UKrsquos synchrotron science facility as well as STFCrsquos
ISIS Neutron Facility and Oak Ridge National Laboratory
the UKrsquos and USArsquos world-leading neutron facilities re-
spectively to prove that the sponge works under real-life
conditions
Professor Martin Schroumlder Dean of the Faculty of Sci-
ence at Nottingham said in the news release ldquoIt is a very
important to be able to separate different hydrocarbons ef-
fectively and efficiently with low-energy consumption Po-rous solids such as the metal-organic framework system
studied here represent important materials for the future
development of low-energy separation technologies We
are most grateful to our collaborators at ISIS Neutron Fa-
cility Oak Ridge National Laboratory and Diamond Light
Source in bringing this work to fruitionrdquo
Significant Impact on Oil IndustryDr Sihai Yang the winner of Diamond Young Scientist
and BTM Willis Prize is a Senior Research Fellow at
Nottingham He led the project together with Professor
Martin Schroumlder Yang said ldquoWith the help of advancedcentral facilities like Diamond ISIS and ORNL we have
developed a new separation technique which can poten-
tially reduce the energy usage associated with oil petro-
leum and chemical industries which require the separa-
tion of raw hydrocarbons from crude oil
The discovery of the new material NOTT-300 could
have a significant impact on the oil industry by removing
the necessity for some energy-intensive refinement pro-
cesses researchers say
The research was funded by Engineering and Physical
Sciences Research Council (EPSRC) the European Re-
search Council (ERC) The University of Nottingham andLeverhulme Trust
12 | January 2015
Flow Control Magazine
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THE OUTLOOK | News amp Notes
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1645
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 174514 | January 2015 Flow Control Magazine
PPLICATIONS CORNER | Process Instrumentation
This is the final article in a series based on the troubleshoot-
ing of a mysterious unit shutdown due to flowmeter perfor-
mance problems
If yoursquove followed this column for most of 2014 you know
that what should have been a liquid ammonia stream to the
feed plant became problematic due to the occurrence of
bubbles of ammonia gas These bubbles caused an ultrasonic
flowmeter in a unit to indicate zero flow and caused the reactor
to scram (shut down) under warm operating conditions The source of the bubbles was traced back to the pres-
sure drop associated with a control valve located at the
exit of the liquid ammonia tank farm
This issue was resolved by identifying the problem
and fixing it at its source This was a pragmatic ap-
proach at the time (early 1980s) given the operation
of the cooling system in the unit and the limited selec-
tion of applicable flowmeter technologies
By the early 1990s changes were implemented that elim-
inated all process cooling requirementsmdashexcept for the small
jacketed cooler upstream of the liquid ammonia flowmeter In
other words after these changes the entire cooling system
would be operated and maintained to cool a few meters of
one small ammonia pipe Coincidently at about the same
time Coriolis mass flowmeters became more mature and
could reasonably measure the mass flow of liquid streams
with homogeneous low levels of vapor
The convergence of these two events resulted in another
approach to the problem that was not available in the early
1980smdashie install a Coriolis flowmeter that could operate in
the presence of bubbles The purchase and installation of a
Coriolis mass flowmeter was given high priority given its im-pact on unit operation economics and safety (by eliminating
the ldquomidget-makerrdquo (see March 2014 page 14))
Plant requirements and the technology that can meet
plant needs keep changing An excellent solution today can
become outdated in just a few years However there are few
substitutes for understanding fundamentals when addressing
a problem In other words there can be more than one way
to skin a cat FC
wwwspitzerandboyescom
Problem Solved AgainA Coriolis mass flowmeter provides a better solution
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bull Wide range of pressuresettings
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anti-siphon applications
Write in 10 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
David W Spitzer
Ammonia Gas | Coriolis Flowmeter | David W Spitzer | Scram | Troubleshooting
FLOWSTREAM Find related content flowcontrolnetworkcom
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and Boyes
LLC offering engineering seminars strategic marketingconsulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer can be reached at 845 623-
1830 or at wwwspitzerandboyescom
The purchase and installation of a
Coriolis mass flowmeter was given
high priority given its impact on unit
operation economics and safetyldquordquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1845
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7232019 Flow Control January 2015
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Process improvements to increase yield or cut manufactur-
ing costs typically require enhanced process control but the
installed base of measurement instrumentation in a process
plant may simply be unable to facilitate improvements because
of age inadequate performance or unreliability Maintenance
cost and unscheduled process downtime for an aging process
plant can be very damaging to the balance sheet Upgrading
to new more accurate and more reliable instrumentation can
be prohibitively expensive New plant construction must alsomaintain a focus on optimizing costs for the process control
infrastructure The budget approval decision for new plant
construction must weigh such costs against projected market
conditions for the products that the plant is intended to manu-facture In todayrsquos volatile global marketplace return on invest-
ment calculations for plant upgrade or new plant construction
projects may go through several iterations before the trigger is
finally pulled or indeed not pulled
This article describes advances in two-wire instrumenta-
tion specifically in relation to flowmeters that have taken
place in the past few years and the significant cost benefits
that this new technology can realize for plant builders and op-
erators in terms of capital investment and cost of ownership
The Significance of Two-Wire Loop Power
A survey involving 204 participants in the chemical indus-try across Germany Switzerland the UK Canada and the
United States (Manfred Koenig PhD KIM Ludwigshafen
Germany 2006) revealed an 87 percent preference for two-
wire instrumentation versus four-wire in process applications
and 89 percent for utilities This overwhelming preference
may stem from the fact that older process plants were built
with two-wire twisted-pair cable networks connecting all
process units and measuring instruments together in an
overall plant control scheme
However these existing cables are relatively unsophisti-
cated and incapable of supporting anything but low-energy
instrumentation that is insensitive to interference from otherelectrical sources that might be sharing the same cable con-
duit Further the low energy levels supported by these two-
wire loops are more easily rendered safe in terms of explo-
sive risk in hazardous areas containing flammable materials
Many older process plants are also likely to have a significant
installed base of flowmeters employing pre-war (pre-1945)
technology such as positive displacement (PD) turbine vari-
able area (VA or Rotameter) and differential pressure (dP)
Market data firm Flow Research Inc (wwwflowresearch
com) indicates collectively a future compound negative annual
growth rate approaching minus 3 percent to 5 percent for PD
turbine and VA flowmeter types while dP is expected to keeppace with market growth (World Market for Flowmeters 2010)
YSTEMS DESIGN | Flow Measurement
16 | January 2015
Flow Control Magazine
The Two-Wire
ADVANTAGENew wiring options enable modern instrumentsto drive cost savings in existing plant systems
By Steve Milford
Advances in two-wire instrumentation have enabled mod- ern technology to be employed to the advantage of older
plant and process systems
Some chemical manufacturing plants are
competing for survival not only externally
against other global companies but also
internally among the global facilities of theirown company Other industry sectors face
similar challenges
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2045wwwflowcontrolnetworkcom January 2015 | 17
The Need to Replace Older TechnologiesUntil the 21st century two-wire loops were only able
to support these relatively unsophisticated instruments
which convert their measurement by various means into a
4-20mA output or pulse signal to the control system The
more advanced post-war flowmeter technologies such as
Coriolis ultrasonic or electromagnetic flowmeters have
until just eight years ago required a dedicated power sup-
ply for their function in addition to the output loop and
thus a four-wire infrastructure was required as a minimum
Therefore upgrading older two-wire meter devices to moremodern four-wire technology could require significant
expenditure in terms of the installation of separate power
cables and supply modules
There was a major breakthrough in 2006 when a true
two-wire loop-powered inline liquid ultrasonic flowmeter
was introduced (Figure 1) The nature of this breakthrough
was innovation in device power management This was the
missing piece up to that point because to be a true loop-
powered device the meter had to directly provide a full 16
mA span using less than 36 mA of remaining loop current
and less than 1 Watt of electrical energy The flowmeter
operated on a single 4-20 mA HART two-wire loop wasremotely powered by a DC supply was certified Class 1 Divi-
sion 1 and could be deployed as Intrinsically Safe through
the use of an approved safety barrier
A true two-wire loop-powered Coriolis flowmeter followed
in 2011 (Figure 2) employing a new and more advanced
common electronics platform A two-wire loop-powered inline
ultrasonic flowmeter for low-pressure gas was introduced in
2012 and a second two-wire loop-powered Coriolis meter fol-
lowed in 2013 offering improved measurement performance
and an additional high-performance meter tube material
Electromagnetic and vortex flowmeters had already been
available for some years in two-wire loop-powered form butimproved performance resulted as these designs were incor-
COURTESYENDRESS+HAUSER
Figure 1 A two-wire ultrasonic flow- meter released in 2006 operated ona single 4-20 mA two-wire loop
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I I I I LL I
I I I I LL I
copy COPYRIGHT 2015 OMEGA ENGINEERING INC ALL RIGHTS RESERVED
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Prices listed are those in effect at the time of publication and are subject to change without noticePlease contact OMEGArsquos sales department for current prices
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FPD3300 SeriesStarts at
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Positive Displacement Flow Meterfor Fuels and Oils
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Thermal Imaging CameraFor Inspection andFactory Diagnosis
Note Not for ExportUSA Only
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 214518 | January 2015
Flow Control Magazine
porated into their new common electron-
ics platform in 2013 So all the ldquomodernrdquo
flow measurement technologies mdash that
is to say those introduced post-war mdash
have become available as two-wire loop-
powered devices with one exception
namely thermal mass (thermal disper-
sion) meters Unfortunately the power
requirements for this technology exceed
what is currently deemed possible withtwo-wire loop-power management
Payback forTechnology UpgradeConsider a 1rdquo process line
containing a liquid process
ingredient costing $1lb at a
mass flowrate of 150 lbmin-
ute We have $150minute
flowing in the line translating
to $9000hour and $72000
per eight-hour shift That cal-culates further to $360000
per five-day working week and
for a working year of 40 weeks for
example that is $144 million Assume
the existing device is a turbine flowmeter
Now imagine a two-wire loop-
powered Coriolis mass flowmeter is
installed in place of the existing meter
The line would need to be drained and
probably one process flange replaced
allowing the Coriolis to fit mechanically
in place of the turbine However thetwo-wire loop already used for carrying
the existing meterrsquos flow signal to the
control room can be used unaltered
for the complete electrical installation
aspects of the Coriolis flowmeter
The upside of the change is signifi-
cant and clear cut Assuming the exist-
ing meter measurement uncertainty was02 percent of reading then measure-
ment uncertainty improves through use
of Coriolis to 01 percent of reading
giving a 01100 x $14400000 im-
provement in control of the ingredient
annually or $14400 A two-wire Coriolis
mass flowmeter with 01 percent mass
flow accuracy would be paid for in ap-
proximately 6-8 months In practice the
improvement in measurement uncer-
tainty would be greater as the operator
would gain temperature and density in-formation from the Coriolis and the mea-
surement would be devoid of any fluid
property dependence Viscosity change
for example can have a major impact on
turbine meter performance Mechanical
wear and tear that turbine meters even-
tually experience which causes them to
under-register flow is precluded by mod-
ern devices like Coriolis
Furthermore if the process ingredient
was being blended with another then ad-
ditional process improvements could berealized through in-line blending control
using Coriolis technology for final density
as the control point It is possible to have
dual 4-20 mA outputs from two-wire
loop-powered meters but as the main
4-20 mA output representing the prima-
ry variable is also HART then an external
HART Loop Converter or HART IO card in
the control system can provide second-
ary tertiary and quaternary variables as
4-20 mA signals A Coriolis meter is trulya multi-variable device Certain two-wire
devices are also available with Profibus
or Foundation Fieldbus communication
Cutting Wiring CostsIn 2003 WIBEXERA (International
Instrument Usersrsquo Associations) Report
T 2732 X 03 was published and it pro- vided an average survey of prices quoted
in projects at that time for the provision
of power supplies for four-wire instru-
ments The price ranged from euro1200
to euro1800 per instrument depending
upon design and plant characteristics
for an average cost of euro1500 (about
$2000) It would be reasonable to
assume an inflationary factor of 2 per-
cent per annum giving an approximate
current-day figure of $2500
From another source within thechemical industry an estimation of
$40foot to $50foot was given for in-
stallation of four-wire cabling For a
linear 50-foot cable run with for ex-
ample a 10-foot vertical at each end
this equates to $3150 Actual costs
and budget estimates have been given
as high as $10000
The Extent of the Opportunity The modern post-war flow measure-
ment technologies have different powerrequirements and consequently they
are not all available for the
same size range in two-wire
loop-power form For example
two-wire Coriolis flowmeters
are limited to 2rdquo diameter
electromagnetic and inline
low-pressure gas ultrasonics
are limited to 8rdquo and vortex
and inline liquid ultrasonic are
limited to 12rdquo
Nevertheless for thechemical industry in particu-
lar perhaps two-thirds of the
process pipes in a plant will be no larger
than 2rdquo and even when the host process
pipe is larger a correctly sized flowmeter
can still be less than 2rdquo There is consid-
erable scope for two-wire loop-power to
deliver value for flow measurement ap-
plications with total safety
The virtues of Coriolis technology
have been covered but what about
other two-wire technologies An elec-tromagnetic flowmeter in two-wire form
YSTEMS DESIGN | Flow Measurement
In todayrsquos volatile global mar-
ketplace return on investment
calculations for plant upgrade or
new plant construction projects
may go through several itera-
tions before the trigger is finally
pulled or indeed not pulled
ldquo
rdquo
COURTESYENDRESS+HAUSER
Figure 2 Two-wire Coriolis flowme- ters became available in 2011
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2245
can be used on water wastewater or
a light water-based slurry provided the
fluid has around a 20 microSeimenscenti-
metre (microScm) electrical conductivity
A magnetic flowmeter is full bore un-
less flowrates dictate a reduced meter
size in the interests of performance and
so there are no intrusions into the flow
stream and no pressure loss An accu-
racy of 05 percent of reading is normal
from a two-wire magnetic meter and a
modest five diameters (5D) of straight in-let run is needed to avoid error from up-
stream flow disturbances When the fluid
exhibits insufficient conductivity then
the same performance and installation
requirements can be met by an inline ul-
trasonic flowmeter provided the liquid is
essentially clean and bubble-free
For gas or steam applications a vor-
tex meter is the normal choice Using a
built-in temperature sensor a two-wire
loop-powered vortex meter can calculate
mass flow of saturated steam using in-ternal steam tables An external pressure
input allows mass flow of steam to be ac-
curately calculated even when saturated
steam becomes superheated as can oc-
cur downstream of a pressure regulating
valve With mass flow known the vortex
meter can calculate energy and heat flow
A new and exciting development is
the ability of the vortex meter to indicate
wet steam and calculate dryness frac-
tion or steam quality For safety and ef-
ficiency saturated steam should be dry
and free from condensate that is to say
it should possess a high steam quality
factor However the dry or wet state of
saturated steam can sit on a knife-edge
and shift to the opposing state due to
the slightest change in process condi-
tions Rapid and reliable indication of
this change of state is now available
Perhaps the most astonishingachievement in the power management
of two-wire loop-power flowmeters is
that of the ultrasonic biogas meter It is
now possible not only to measure the
flow of wet dirty variable composition
and low-pressure anaerobic digester
gas landfill gas and coal bed methane
gas with a two-wire loop-powered ultra-
sonic flowmeter but also the same de-
vice uses an inbuilt temperature sensor
in combination with measured sound
velocity to calculate methane contentcalorific value and energy flow
Technology to Take UsForwardModern flow technologies provide instru-
ment engineers with vital self-monitoring
information The format of such infor-
mation is easier to understand and act
upon when presented in accordance
with harmonized international guidelines
for online plant asset management eg
NAMUR Standard 107
Continuous plain-text self-diagnostic
and process-related information with
suggested remedies (Figure 3) make it
possible for instrument engineers andoperators to take action at the appro-
priate time mdash immediately or during
the next scheduled shutdown mdash saving
time and money by knowing the exact
health of their measuring point and the
probable actions required to rectify any
abnormal conditions Device verifica-
tion offering third-party validated trace-
ability can be performed on demand ei-
ther locally or remotely from the control
room without the expense of a man in
the field Calibration is then avoided ordeferred without process interruption
Where a process plant has a large
installed base of older mechanical tech-
nologies the decision to embark upon a
program of replacement for plant mod-
ernization cannot of course be taken
easily There are the stocks of spare
parts to consider along with the plant
instrument technicians who are trained
on and at ease with the old devices
However a process plant that retains
the older technology going forward willbe at risk and may find it increasingly
difficult or even impossible to maintain
a cost position that competes effective-
ly in the global market FC
wwwusendresscom
wwwflowcontrolnetworkcom January 2015 | 19
Steve Milford
is a Flow Product
Business Manager
for Endress+Hauser
Inc in Greenwood
Ind He has been
involved in flow
measurement since
1983 and has been
actively involved with standards devel-
opment for flow technology within the
International Standards Organization
(ISO) and the British Standards
Institute Mr Milford can be reached
at stevemilfordusendresscom
Steve Milford
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Coriolis Flowmeter | Magnetic Flowmeter | Two-Wire | Ultrasonic Flowmeter | Vortex Flowmeter
Figure 3 A modern instrumentrsquos display module can provide continuous plain- text self-diagnostic and process-related information
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2345
The bottom line is the volume of gas under one set of
pressure and temperature conditions is not the same as it
would be for the gas under different conditions Why is thisimportant Without compensation for compressibility read-
ings taken by gas flowmeters can result in measurementsmdash
and costs to the buyermdashsignificantly lower or higher than they
should be
The flow of gas in a system can be accounted for and
reported in a number of ways such as by volume by mass
flowrate and by energy Inline turbine meters can offer both
reliability and accuracy in measuring gas flow when matched
with a monitor capable of calculating and displaying results
that have been adjusted for the nature of the gas and impor-
tantly the pressure and temperature
Measuring Flow with an Inline TurbineFlowmeter
With an inline turbine meter gas flows into the meter through
a length of piping that helps to pre-condition the flow by
reducing undesirable swirls and asymmetry Where consid-
ered necessary a flow straightener may even be installed in
line to create a uniform flow profile to the extent possible
As can be seen in Figure 1 a rotor support within the tur-
bine housing further conditions the flow and directs it through
the blades of the rotor High-precision ball bearings allow the
rotor to freely rotate on the shaft
The rotorrsquos rotational speed is directly proportional to the velocity of the fluid passing through the meter The rotor itself
incorporates magnets (or magnetic blades depending on thedesign) while the housing is non-magnetic
A proximity sensor (also known as a pickup coil) is located
in line with the rotor and detects the electrical pulses gener-
ated by the ferrous rotor spinning through the magnetic field
Each pulse represents a discrete volume of gas The out-
put frequency provides the indication of the gas flow rate and
the accumulated pulses over a specified time represent the
total volume of fluid for that measurement period
Need for Calibration The flowrate of the gas through the meter cannot be deter-
mined accurately unless the meter is calibrated The fac-tory calibration determines the meterrsquos constant known
as a K-factor which is then inputted into the gas monitor
PPLICATION NOTES | Flow Measurement
20 | January 2015
Flow Control Magazine
COMPENSATING for
Compressibility inMeasuring Gas Flow Why K-factor adjustment is essential foraccurate inline turbine flow measurement
Unlike crude oil and other liquid fossilfuels natural gas poses a challenge
in monitoring the quantity of gas flowing
through pipelines While liquids do not com-
press gases do and the mass flowrate of
gas being transmitted through gathering
lines depends on both the pressure and
temperature
By Kevin Clark
Figure 1 Internal components of a liquid turbine flowmeter
C O U R T E S Y
T U R B I N E S
I N C
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2445
Wondering Whether the
Pump Guy Seminar
Is for YouCheck out the ldquoPump Guy Insightsrdquo
video series flwctrlcompginsights
PUMP GUY INSIGHT 1NPSHa vs NPSHrmdashWhy all pumps need gauges
PUMP GUY INSIGHT 3How to Operate Your Pump at Best Efficiency
PUMP GUY INSIGHT 5Head vs Flow
PUMP GUY INSIGHT 2 Your Pumps Are Constantly Moving On Their Curves
PUMP GUY INSIGHT 4 The Role of the Pump Reliability Chain
PUMP GUY INSIGHT 6How to Read a Pump Curve
PARTNER SPONSORSFor more information and to register
for upcoming Pump Guy Seminars
visit FlowControlNetworkcomPumpGuy
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2545
PPLICATION NOTES | Flow Measurement
22 | January 2015
Flow Control Magazine
Gas flowmeters measure the actual volume of gas passing
through the meter per minute irrespective of pressure and
temperature1
The volumetric flowrate of a gas is often corrected to
ldquostandardizedrdquo conditions of pressure and temperature While
ldquostandardrdquo conditions can vary depending on the definition
in the US this typically means a pressure of 1473 PSIA(pounds per square inch absolute) and a temperature of 60 F
The flowrate measurement is reported in standard cubic feet
per minute (SCFM)
Compensating for changes in pressure and temperature is
critical Consider a meter system setup for flowing conditions
of 60 PSIG (pounds per square inch gauge) and 60 F and the
line pressure decreases to 50 PSIG while the temperature
remains constant The difference in SCFM between the two
is more than 15 percent which would cost the buyer more
for the gas than it should As Table 1 demonstrates even a
small variation in pressure will result in a surprisingly high er-
ror percentage
Automation of the K-Factor The K-factor is established by an initial factory calibration In
the case of a non-compensated flow monitor any variations
in pressure and temperature will result in manual adjust-
ments needed to the K-factor In order to maintain accurate
flow measurement users must monitor pressure and temper-
ature and make corresponding adjustments to the K-factor To eliminate these manual adjustments some suppliers offer
a flow monitor that automatically adjusts for any changes in
pressure and temperature
These monitors provide accurate flow measurement regard-
less of changing environmental conditions in some cases sup-
porting applications with pressures as high as 15000 PSIG and
temperatures between -350 F to 350 F with a standard accura-
cy of +-1 percent over a flow range of 05 ACFM to 650 ACFM
Final NotesDuring the operation of a flowmeter system the ability to obtain
a readout mdash and to adjust for line pressure and temperaturechanges mdash is sometimes compromised by a lack of electric
power This issue is especially true along gas pipelines in remote
areas To overcome this limitation some manufacturers have
designed low-powered flow monitors which can operate for up
to on year on a single lithium D-cell battery
It is important for users to recognize the effects of the
compressibility of gas As such the quantity of a gas flow-
ing through a gas flowmeter depends on the pressure and
temperature In order to ensure accuracy any flowmetering
system must employ a means to correct for these effects
Otherwise the readout is certain to be in error and could be
unnecessarily costing money This is particularly crucial onwellhead production and in billing scenarios FC
wwwturbinesincorporatedcom
Notations1 The measurement factor in the US is known as the
ACFM actual cubic feet per minute (Metric units are typically
ACMH actual cubic meters per hour)
Table 1 Error induced by line pressure changes
Constant Temperature with Varying Pressure
Pressure Temperature PulsesSCF Error
50 60 2556027821 1546
51 60 2517123288 1370
52 60 2479385307 1199
53 60 2442762186 1034
54 60 240720524 873
55 60 237266858 717
56 60 2339108911 566
57 60 2306485356 418
58 60 2274759285 275
59 60 2243894166 136
60 60 2213855422 000
61 60 2184610304 132
62 60 2156127771 261
63 60 2128378378 386
64 60 210133418 508
65 60 2074968632 627
66 60 2049256506 743
67 60 2024173807 857
68 60 1999697703 967
69 60 1975806452 1075
70 60 1952479339 1181 Flow Measurement | K-Factor | Measurement
Accuracy | Turbine Flowmeter
Find related content flowcontrolnetworkcomhellipSearch on
FLOWSTREAM
Kevin Clark is senior develop-
ment engineer for Turbines Research
amp Development LLC Turbine RampD is a
subsidiary and the research and techni-
cal support arm of Turbines Inc which
serves a range of industries and applica-
tions from oil amp gas to cryogenic liquids
to custody transferKevin Clark
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2645
Pumps Bearings amp Seals TECHNOLOGY REPORT
FEATURES
SYSTEMS DESIGN
The ComplicatedCase of
Compressors
withSide-Streams
24 28 32BEST PRACTICES
How PumpingSystems
AffectSealing
Performance
TECH OUTLOOK
BearingSuppliers
Drive Gains InDeveloping
Markets
wwwflowcontrolnetworkcom January 2015 | 23
S P E C I AL S E C T I O N
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2745
The design and operation of compressors with side-
streams has always been difficult because flow entering the
compressor needs to be mixed with the core flow already
in the compressor (compressed in section-1) in a manner
that does not degrade the aerodynamic performance of sur-
rounding sections Minimizing losses and ensuring proper
mixing of the side-stream flow and core-flow are required to
ensure effective performance of a compressor of this sort
Key considerations for an application involving compres-
sors with side-stream flow include
The plant process typically dictates the side-stream
flange pressure
The impellers upstream of the side-stream should
achieve the necessary pressure for the core-flow
The side-stream flow is typically at a temperature dif-
ferent from compressor core-flow temperature
Process plants need some degree of operational flex-
ibility ie the ability to support variations in core-flow condi-
tions and side-stream conditions
Modern process plants are usually specifying more than
one operating conditions (sometimes two or more manda-
tory conditions) which can present challenges to compres-
sors with side-streams Adding to these issues modern
compressors should operate with much higher impeller tip
The COMPLICATED CASE ofCompressors with Side-StreamsConsidering key system design requirements
to ensure operational efficiency By Amin Almasi
4 January 2015
Flow Control Magazine
|
y
g
Some compressors in certain applications
have one or more incoming side-streams
(or side-loads) that introduce side-stream
flow to mix with the core flow In other words
a radial side-stream inlet is utilized in multi-
impeller centrifugal compressors to introduce
additional gas into the mid-stage of a com-
pressor This design enables optimization in
some process plants However the flow dis-
tribution after the junction of the side-stream
and the main return channel of the upstream
section can significantly affect the perfor-mance of the next section of compressor
In most cases the pressure levels at these
side-streams should be accurately predicted
to meet the theoretical performance
Compressor station at a natural gas processing plant
R U D M E R Z W E R V E R I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2845
speeds and inlet Mach numbers compared to previous
generations of compressor technology
Likewise side-streams are now com-
monly used with medium-sized and
large-sized compressors (eg 1ndash60
MW) The costs associated with cor-
rections on side-stream compres-
sor applicationsmdashany repair
inefficient operation and power
lossesmdashwould be very high Fur-
ther compressors with side-streams
are usually sensitive and difficult
machines to operate In particular
performance curves (performance
pressures efficiency etc) are sen-
sitive to suction inlet conditionsside-stream inlet conditions vol-
ume flow ratio (side-stream vol-
ume to core-flow volume) and side-stream losses
Compressors with side-stream often perform far below
expectations The main reason is that side-stream compres-
sors are different than conventional compressors (without
a side-stream) in design and operation For a compressor
with side-streams tighter tolerances in operating conditions
must be identified and applied Uncontrolled variations of
suction pressure or side-stream pressure are major prob-
lems Another major issue is the variations of the flow ratio
(side-stream flow to core-flow)
Compressor Side-Stream amp Mixing SectionIn many centrifugal compressors the portion of the side-
stream system from the flange connection to the mixing
section is similar to a compressor inlet A great challenge
is ensuring the mixing section provides circumferentially
uniform merged-flow with minimum losses This can be
achieved via effective design of the inlet configuration and
mixing section of the side-stream compressor such that
the impeller can be maintained over the whole operating
range of the compressor In many cases while there are
mixing sections provided for the machine the flows do not
completely mix before entering the impeller of the section-2
(the impeller after the mixing section) Non-uniformity at
inlet flow to the impeller is a key concern for compressor
performance
Another consideration is a compact design of the side-
stream mixing section Specifically a mixing section with
less axial length is always preferred This axial length can af-
fect the compressor rotor dynam-
ics the rotor length and over-
all compressor performance
(design cost operation and
reliability)
The side-stream exit pressure
(side-stream pressure at inlet
of the mixing section) is mainly
a function of the side-stream
flow velocity and the pres-
sure in the previous section of
the compressor Conversely the side-
stream flange pressure can depend on
side-stream flow velocity and section-1
exit conditions Therefore the side-stream
inlet flange volume flow is a function of theflange pressure compressibility (at that
pressure and temperature) and mass flow
Some engineers assume that the side-stream flange pres-
sure is equal to the inlet pressure of the first impeller of the
section-2 This is not true The mixed total pressure can be
estimated on a mass-averaged basis using side-stream total
pressure and return channel exit (section-1) total pressure
In some designs because of the lower static pressure at
the side-stream exit the total pressure at the return channel
exit is lower even though the velocity upstream is roughly
matched for both streams The pressure usually increased
at the returned channel but it can be reduced again at the
side-stream exit While simple in nature this can have an
impact on the prediction of pressure at the side-stream exit
and overall mixing section performance Based on basic flow
principles it was usually assumed that the static pressure
was equal between both flow streams at the mixing location
While this assumption might be used in rough calculations
the accurate simulations have shown this assumption is not
true In fact there are some points (for instance the shroud
wall at the exit of the return channel and the hub wall at
the exit of the side-stream) where this assumption is true
However this is not valid for all locations There are pressure
changes that occur from a side-stream flange to the inlet
of the next section (section-2) which depend on different
factors The first factor is the frictional losses due to side-
stream geometry from side-stream flange to plenum mix-
ing section etc The other factors are pressure changes due
to local curvature and geometry details of mixing section
Another consideration is the operation of a compressor
with side-stream at part-load The performance of the side-
wwwflowcontrolnetworkcom January 2015 25
Figure 1 An example of a centrifugalcompressor with side-stream
COURTESY SIEMENS
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 29456 January 2015
Flow Control Magazine
|
y
g
stream path the mixing section and
the downstream impellers when ma-
chine is operated at part-load or even
off-design operating flows will result
in additional compressor performance
problems In such a case both veloc-
ity profiles and pressure variations in
various parts (side-stream path mixing
section etc) will be different resulting
in complicated flow patterns and com-
plex aerodynamics behaviors
Side-Stream CompressorSectional Performance
Typically vendor-supplied compressor
performance curves reflect flange-to-flange performance because that is
what the plant engineers need to
evaluate the proper operation of their
system (for example from suction to
side-stream and from side-stream to
discharge) In many cases compres-
sor vendors also provide the over-
all compressor performance curves
and performance curves for section-1
(from suction to side-stream) and sec-
tion-2 (from side-stream to discharge)
Flange-to-flange data if not interpret-
ed properly can lead to false conclu-
sions about the relative performance
of individual sections of a compression
system For example if side-stream
losses from the flange to mixing sec-
tion are attributed to the downstream
section (section-2) it will cause the
downstream section (section-2) to
appear low in performance while the
upstream section (section-1) will show
high performance levels
An important behavior to con-
sider is when the actual side-stream
pressure is different than the rated
side-stream pressure When the side-
stream pressure is slightly higher than
the outlet pressure of the section-1
it (section-1) shows a relatively higher
performance compared to the real sec-
tion-1 performance In some cases
the performance of section-1 could be
considerably higher than section-2 In
other words when performance is de-
termined flange to flange the higher
flange pressure is seen as extra ldquopseu-
dordquo work done by the section (since this
is an inconsistent thermodynamic vol-
ume) resulting in a relatively high sec-
tional efficiency (section-1 shows a rel-
atively high efficiency) This is the case
for many compressors with side-stream
because the whole system is designed
(or specifically the side-stream location
is selected) in a way aimed at main-
taining the real side-stream pressure(side-stream inlet) above the section-1
outlet pressure because if the real side-
stream pressure becomes lower than
the section-1 outlet pressure the flow
may (theoretically) reverse
This is particularly important when
the side-stream mass flow is much
lower than the mass flow of core-flow
The above-mentioned reasons explain
why in many simulations calcula-
tions and performance reports related
to compressors with side-stream the
section-1 shows a relatively good ef-
ficiency and section-2 appears low in
efficiency
When the side-stream pressure is
slightly lower than the outlet pressure
of the section-1 the section-1 might
show a relatively lower performance
compared to section-2 This could oc-
cur in some recycle services where the
side-stream is actually a recycle flow
with a mass flow around two to five
times the core-flow The side-stream
(recycle) flow is returned from down-
stream of the compressor to be slightly
compressed and recycled to the down-
stream Such a recycled side-stream
compressor can present unique chal-
lenges for design and operation This
kind of machine usually needs very
special operating procedures and very
fine adjustments regarding operating
pressures and flows
Side-Stream Compressor
Performance amp Operation An important consideration is the sen-
sitivity of compressor overall perfor-
mance curve and sectional perfor-
mance curves to the flow ratio (ratio
of side-stream flow to core-flow) and
to the inlet conditions Variations in
the flow and pressure of the main
suction and side-stream inlet should
be controlled within tight tolerances
For compressors with side-stream the ASME PTC-10 code stipulates limits on
flow ratio (side-stream volume to core-
flow volume) The acceptable variation
in volume flow ratio in a compressor
with a side-stream is +-5 percent as
per ASME PTC code The requested
side-stream pressure tolerance is not
usually specified in compressor codes
but it should be around +- 2 percent
(or sometimes +- 25 percent)
Variance in flow ratio impacts the
velocity levels where the two streams
merge Significant variation in the ve-
locity profile upstream of the impeller
changes the incidence on the blade
leading edge of the following impel-
ler This change in incidence leads to a
change in sectional performance over-
all compressor performance and train
efficiency
If the flow ratio is varied between 95
percent and 105 percent (tolerances
specified in the ASME PTC-10 code)
the flange pressure changes accord-
ingly resulting in a change in the sec-
tional performance and overall perfor-
mance The sectional efficiency varies
sometimes more than +- 4 percent
This variance reduces as the flow is de-
creased toward surge However as the
flow is increased toward overload the
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3045wwwflowcontrolnetworkcom January 2015 27
variance increases up to higher values
(even in some cases three to five times
compared to variations near the surge
zone) For example in a case study
for a compressor with side-streams a
+- 5 percent variation in flow ratio and
associated changes (pressures losses
etc) the sectional efficiency reduced by
approximately 34 percent at the rated
flow at allowable operating points at
the end of curve (near the overload
ie choke) efficiency reduced by ap-
proximately 55 percent These results
show that the variation in sectional
performance and overall performance
due to flow ratio is highest at operat-ing points near the overload and low-
est at operating points near the surge
For compressors which work most of
the time at high flow (flow higher than
rated flow and discharge pressure low-
er than rated pressure) the effects of
flow ratio deviations (and subsequently
efficiency reduction) would be higher
than compressors working on the left-
hand side of curve (say with sufficient
margins near the surge)
In the compressor codes (such as
API 617) the compressor power varia-
tions should be maintained below 4
percent However in some applica-
tions clients require tighter tolerances
on the consumed power sometimes
below 2 percent (or even below 15
percent) Some studies suggest while
+- 5 percent of volume flow ratio is
suitable for performance test as per
ASME PTC-10 code some plants re-
quire tighter control on the consumed
power and compressor performance
(lower limits on the efficiency) the tol-
erances on the volume flow ratio could
be tighter than ASME PTC code In this
regard +- 4 percent tolerance can be
suggested on the volume flow ratio (ra-
tio of side-stream flow to core-flow) of
compressors with side-streams
Based on operational experiences
acceptable variations in volume flow
ratio and inlet pressures (suction inlet
and side-stream inlet) of a compressor
with side-streams are +- 4 percent
and +- 2 percent respectively
Another important consideration is
the required adjustments for the flow
ratio (side-stream flow to core-flow)
Compressors with side-stream usually
require fixed side-stream flange pres-
sures For a compressor with some variations in operation conditions (even
small changes) it is not usually pos-
sible to achieve optimum operation by
keeping the flow ratio (side-stream to
core-flow) constant The flow ratio has
to be adjusted according to the inlet
flow at which the machine is operating
in order to get the required correspond-
ing side-stream flange pressure
Thermal changes have also been
known to cause some instability in
centrifugal compressors An example is
the thermal-induced change of resid-
ual unbalance For compressors with
side-streams which feature tempera-
ture differences between core-flow and
side-stream flow the thermal behav-
ior of the compressor is usually more
complex and requires more attention
Heavy Gas ChallengeHeavy gases (such as heavy hydrocar-
bon gases eg propane propylene
MTBE (Methyl Tertiary Butyl Ether))
have very low gas sonic velocities that
produce high Mach numbers in the
aerodynamic flow paths For these
services because of high Mach num-
ber high flow coefficient stages have
very narrow flow maps characterized
by limited surge and choke margins
Compressors with side-streams in
these services present great challeng-
es This is to say the side-streams and
associated mixing further complicate
design operation and performance
prediction because the pressure tem-
perature and flow conditions at each
one of these side-streams as well
as at the exit of the machine require
stringent tolerances to optimize the
overall efficiency and performance
As such it is important to accuratelymodel design operate and moni-
tor performance characteristics of any
impellers diffusers return channels
and generally all flow-path components
in a compressor with side-stream FC
Amin Almasi
is a senior rotating
machine consultant
in Australia He is
a chartered profes- sional engineer of
Engineers Australia
(MIEAust CPEng ndash
Mechanical) and
IMechE (CEng MIMechE) holds
bachelorrsquos and masterrsquos degrees
in Mechanical Engineering and is
a registered professional engineer
in Queensland He specializes in
rotating machines including cen-
trifugal screw and reciprocating
compressors gas turbines steamturbines engines pumps subsea
offshore rotating machines LNG
units condition monitoring and reli-
ability Mr Almasi is an active mem-
ber of Engineers Australia IMechE
ASME and SPE He can be reached
at aminalmasiymailcom
Amin Almasi
Compressor | Gas Flow | Performance Curve | Side-Stream Flow
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3145
The pressure in the stuffing box
containing the packing can be estimat-
ed by the following equation
SBP = [Discharge ndash Suction] 3 + Suction
Pressure at the bottom of the stuff-
ing box will be higher than the suction
pressure but considerably lower than
the discharge pressure It should be
noted this calculation will yield a con-
servative estimate of stuffing box pres-
sure that can be further reduced by
pump design
A hole in the stuffing box serves as
a port for injecting clean fluid that cir-
culates around a lantern ring aligned
under the flush port The fluid flushes
solids back into the process to protect
the packing from abrasive wear If the
clean fluid is injected at a pressure ex-
ceeding that at the bottom of the stuff-
ing box some of it will leak back into
the process and some will leak out to
the atmosphere Recommended flush
injection pressure is 15ndash30 PSI (1ndash2
Bar) greater than the pressure at the
bottom of the stuffing box
Fluid injection is also used to lubri-
cate and cool dry-running packing that
is subject to frictional heat and to pre-
vent air from entering the pump which
reduces flow and operating efficiency
Centrifugal pumps utilize three
types of impellersmdashopen semi-open
and closed (Figures 2 3 amp 4) Open
designs prevent fluids with large solids
from clogging the impellers but at theexpense of pump efficiency Backing
plates on semi-open designs serve to
trap the fluid for more efficient opera-
tion Closed impellers are for use with
clean fluids since solids could ac-
cumulate in the eye which would re-
quire tearing down the pump to remove
them
Single-Stage CentrifugalPumpsSingle-stage centrifugal pumps typi-
cally have good bearing support of the
shaft with few run-out or ldquowhiprdquo prob-
lems However in some cases they
are subject to cavitation This occurs
in the eye of the impeller where the
fluid is under vacuum If the pressure
is low enough it will cause the material
to vaporize forming air or water vapor
bubbles As the fluid passes through
How Pumping Systems Design Affects Sealing Performance
By Chris Boss
8 January 2015
Flow Control Magazine
|
Understanding how different types of pump designs impact
sealing is critical to optimizing efficiency safety and lon-
gevity of the sealing system Used for a wide variety of media
including clear fluids solutions and slurries single-stage
centrifugal pumps are one of the most common
types (Figure 1) Fluid drawn into these pumps
enters the eye of an impeller that spins itto the outside of its container
or volute building pressure as
it moves toward discharge
Some of this fluid will work
its way behind the impeller
where it must be sealed with
compression packing or a
mechanical seal
Figure 1
Figure 2 Figure 3 Figure 4
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3245
the pump under increasing pressure
these bubbles implode sending shock
and vibration through the impeller
adversely affecting the seal This phe-
nomenon can be mitigated by running
the pump at slower speed and higher
pressure at the suction end to prevent
air from entering the fluid
Double-Ended Split-CasePumpsOperating on the same centrifugal prin-
ciple but slightly different geometry are
double-ended split-case pumps (Figure
5) Fluid enters both ends of the pump
and is directed into the eye of an impel-ler which spins it out of the volute to
discharge Packing is installed on both
the shaft and bearing ends so the stuff-
ing box is exposed only to suction pres-
sure which is usually quite low
Axial Flow Pumps Axial flow pumps operate like hydro
turbines in reverse whereby a propeller
(or axial impeller) pushes the fluid to
discharge (Figure 6)
Since the stuffing box is located
downstream of the propeller at the dis-
charge end of the pump the packing is
exposed to the full discharge pressure
Vertical PumpsVertical turbine pumps are typically
flange-mounted on a floor extending
downward into a water-filled sump
hole (Figure 7) Available as single- or
multi-stage pumps they feature an
impeller or series of impellers rotated
simultaneously by a single shaft The
impellers increase the pressure of the
upward flow subjecting the stuffing box
to full discharge pressure
Vertical pumps can be quite long so
inadequate bearing support can cause
the shaft to run out This can induce
undesirable lateral motion on the pack-
ing Worse the packing may be forced
to serve both as a bearing and a seal To
withstand these conditions the packing
should be resilient elastic and resistant
to deformation These properties rule
out packing such as graphite foil in favor
of fiber-based materials
Multi-Stage PumpsMulti-stage pumps are used for high-
pressure applications such as feeding
the boilers in steam-powered generating
plants Stuffing box pressure can vary
with pump design and number of stag-
es Designed for clean fluids and high
operating speeds these pumps typically
have high- and low-pressure ends with ahydraulic pressure equalization line run-
ning between the stuffing boxes
Like vertical pumps multi-stage
pumps feature a series of impellers to
build fluid discharge pressure In the
case of the six-stage pump pictured in
Figure 8 fluid enters at the drive end
where a stuffing box is exposed to suc-
tion pressure Channeled from one
impeller to the next through the pump
casting the fluid can reach extremely
high pressures at discharge
A second stuffing box located at the
bearing end is exposed to an intermedi-
ate pressure from the third impeller This
pressure is greater than the suction pres-
sure but much less than the discharge
pressure which can reach 2000 PSI
Fortunately the stuffing boxes in
these pumps are not exposed to dis-
charge pressures and typically see be-
low 500 PSI which is within the range
of some packing materials
wwwflowcontrolnetworkcom January 2015 29
Figure 5
Figure 6
Figure 7
Figure 8
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 33450 January 2015
Flow Control Magazine
| Gear PumpsPositive-displacement or gear pumps
operate on a different principle than
centrifugal pumps In external gear
pumps the fluid flows around the out-
side of the gears the intermeshing
of which forces it through the pump
to discharge (Figure 9) This design
makes these pumps particularly suit-
able for use with highly viscous fluids
such as resins emulsions syrups and
adhesives As such they are used for
transfer or metering applications
It should be noted gear pumps will
continue to displace fluid as long as
their shafts are turning which can pose
a problem if a clog occurs at the dis-
charge The resulting buildup of pres-
sure can blow out seals and damage
the pump Therefore most gear pumps
have pressure relief valves to divert
fluid back to the suction side for re-
circulation through the pump Internal
gear pumps operate slightly differently
but also have pressure relief valves to
prevent damage from excessive pres-
sure (Figure 10) In both external and
internal gear pumps the maximum
stuffing box pressure is determined by
these valves
Other rotating equipment includes
mixersagitators which are similar to
pumps in terms of the speeds to which
the packing is exposed There are ba-
sically three types of mixersagitators
top- bottom- and side-entry Top-entry
models are subject to the same con-
cerns about shaft run-out ldquowhiprdquo and
lateral forces on the paddles that are
encountered in some vertical pumps
Although some fluid may splash onto
the packing these mixers basically run
dry so the packing must have the abil-
ity to dissipate the resulting frictional
heat
In bottom-entry mixers the packing
is always exposed to fluid and may also
be exposed to solids requiring abra-
sion-resistance If the seal fails the en-
tire contents of the tank will eventually
drain out onto the bearings the floor
and other components under the stuff-
ing box
The packing in side-entry mixers may
be fully or intermittently exposed to flu-
id as well as side loading and vibration
Aside from media temperature
speed and other application variables
the configurations and operating prin-
ciples of rotary-type pumps exert differ-
ent forces on the seals used to keep
them from leaking These forces can
spell the difference between accept-
able seal performance and failure
Understanding these differences has
important implications that should be
taken into account to assure proper
sealing selection for long-term trou-
ble-free performance FC
wwwgarlockcom
Chris Boss is
a senior applica-
tions engineer for
Garlock Sealing
Technologies in
Palmyra NY He
has held various
positions in produc-
tion engineering
product development and applica-
tions engineering for the companyrsquos
compression packing division He
is a BSME graduate of the State
University of New York at Buffalo Mr
Boss can be reached at 800 448-
6688 or chrisbossgarlockcom
Chris Boss
Cavitation | Centrifugal Pump | Pump Packing | Sealing System
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Figure 9
Figure 10
Aside from media temperature speed and
other application variables the configurations
and operating principles of rotary-type
pumps exert different forces on the seals used
to keep them from leaking These forces can
spell the difference between acceptable seal
performance and failure
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3445
NS IDERNDUSTRIAL AUTOMATION + PROCESS CONTROL
WANT
INFORMATION
ON THE
automationindustry
SUBSCRIBE NOW at wwwiainsidercouk
Published by Spitzer and Boyes LLC Write in 15 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
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Frost says the push from developing
economies is important as the market
is technologically mature and seeing
restricted growth in developed econo-
mies This is particularly true in Europe
and North America where recent finan-
cial insta-
bility has
reduced capital expenditure across end-
user industries
Bill Moore senior vice president of
sales development and channel man-
agement for global bearings manufac-
turer SKF says ldquosmartrdquo products and
the expansion of robust reliability pro-
grams are helping to drive new invest-
ment particularly in developed coun-
tries where the cost to compete is
high Frost says the magnitude of
the existing global installed base will
strengthen the need for replacement
and upgrades adding to market de-
mand as well
Frost says despite the potential
in developing economies the focus
on price as a product differentiator
may lead to intense price pressures
among manufacturers and bring down
the value of the overall market in the
short term The growing trend among
consumers to choose low-cost Chinese
imports will complicate this challenge
As price and quality become stan-
dardized across the globe customers
will base more of their purchasing deci-
sions on value-added services accord-
ing to Frost This will push manufactur-
ers to create more maintenance-free
solutions such as lubrication-free
bearings that offer end-users savings
on service and replacement costs and
reduce downtimeldquoOffering a complete line of prod-
ucts with comprehensive services will
be another feather in the cap of ven-
dors looking to widen their consumer
baserdquo notes Frost Industrial Automa-
tion and Process Control Research
Analyst Guru Mahesh
Moore says the trend of outsourcing
manufacturing to regions where labor
and production costs are favorable is
becoming less of a factor
ldquoThe days when cheap labor made
a significant difference in where a prod-
uct is manufactured mdash particularly high
value-added products or high weight
and bulk products mdash are coming to
an end as the cost of transportation
storage and inventory balance out the
benefits of production costs where la-
bor is a smaller percentage of the cost
of manufacturingrdquo Moore says ldquoLocal
manufacturing development will indeed
come to developing countries as their
ability to create markets that generate
economies of scale that support local
production is a clear trend and one that
all manufacturers will pay attention tordquo
Moore says that development of
maintenance-free or predictive tech-
nologies and products will be a sig-
nificant advantage to everyone in the
Bearing amp Coupling Manufacturers Focus
onDEVELOPING Economies
amp EFFICIENCY InnovationBy Amy W Richardson
2 January 2015
Flow Control Magazine
|
gy
Anew study from Frost amp Sullivan (wwwfrostcom) fore-
casts steady growth for the overall bearings and couplings
market based on rapid industrial development in high-growth
regions Specifically Frost predicts development in Mexico
Indonesia Nigeria Turkey Brazil Russia India and Chinawill help boost the bearings amp couplings market from $2206
billion in 2013 to an estimated $2676 billion in 2018
The development of maintenance-freeor predictive technologies will helpboost growth in the bearings market For example SKF is developing products that will automatically notifyusers when a bearing or mechanicalrotating component is approachingthe end of its useful life Pictured hereis an SKF Microlog analyzer a por- table condition monitoring tool
COURTESY SKF
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
improved productivity through simplified solutions The powerful technology and tools ensure repeatable
reliable accurate measurements Easier access to process data allows for better troubleshooting process
optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
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1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
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4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
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Key System Features
7232019 Flow Control January 2015
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FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
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instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
services provided for the
mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
Brought to you by Beamex
Your Source For Fluid Handling Videos
Go towwwflowcontrolnetworkcomfreeinfo
Select appropriate issue ofFlow Control Magazine
Select advertisements thatinterest you
Enter your email amp clickldquoSubmit Requestrdquo
1
2
3
4
PRODUCT
INFORMATION
ONLINE
Follow these 4 steps to receive freeproduct information from suppliers
FREE
FEATURED VIDEO How to Calibrate aPressure Measurement Loop
For more information about FlowTube
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4245
THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
Name ________________________________________________________________
Title _________________________________________________________________
Company _____________________________________________________________
AddressCityStateZip __________________________________________________
______________________________________________________________________
Phone ________________________________________________________________
E-Mail ________________________________________________________________
One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545
![Page 5: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/5.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 545
featurescontents
16 The Two-Wire Advantage
By Steve Milford Advances in two-wire instrumentation specifically in relation to flow-
meters have enabled significant cost benefits for new technology in-
stallations in terms of capital investment and cost of ownership
20 Compensating for CompressibilityIn Gas Flow MeasurementBy Kevin Clark
K-factor adjustment is a key factor in ensuring accurate gas flow mea-
surement for inline turbine meters The K-factor is established by an
initial factory calibration In the case of a non-compensated flow moni-
tor any variations in pressure and temperature will require manual
adjustments to the K-factor
2 | January 2015 Flow Control Magazine
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 qualied subscribers Non-qualied subscrip-
tion rates in the US 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 t he Circulation
Manager for more wire transfer information Single copies $10
per issue in the US and Canada Single copies $15 per is-
sue in all other countries All subscription payments are due in
US funds
POSTMASTER Send address changes to Flow Control PO BOX
2174 Skokie IL 60076-7874 Periodical postage rates paid at
Subscription Information Toll Free 8667214807Outside US 8477631867Mail PO Box 2174Skokie IL 60076-7874E-mail flowcontrolhalldatacom
SubscribeRenewChange of Addresswwwflowcontrolnetworkcomsubscribe
Birmingham AL 35242 and additional mailing ofces
copy Entire contents copyright 2015 No portion of this publica-
tion may be reproduced in any form without written permis-
sion of the publisher Views expressed by the bylined con-
tributors should not be construed as reecting the opinion
of this publication Publication of productservice information
should not be deemed as a recommendation by the publisher
Editorial contributions are accepted from the uid handling
industry Contact the editor for details Productservice infor-
mation 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
1 616
Pumps Bearings amp Seals Technology Report SPECIAL SECTION PAGE 23
24 The Complicated Case of Compressors
with Side-StreamsBy Amin Almasi
28 How Pumping Systems Design AffectsSealing PerformanceBy Chris Boss
32
Bearings amp Couplings Suppliers Position
to Drive Market GrowthBy Amy W Richardson
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 645
Do you know whatrsquos
gone out the window
at your facility
Magnetrolreg energy management solutions monitor and measure the energyflowing through your facility to reduce utility costs and make processes moreefficient Easy to install and operate TA2 thermal flow meters provide you withan efficient environmentally responsible way to manage compressed air andnatural gas cost centers
Make MAGNETROL Thermatel reg TA2 mass flowmeters part of your energy management strategyVisit magnetrolcomthermalmassflow or contact
your MAGNETROL representative for more information
Measure and control your compressed
air and natural gas energy costs with
Thermatelreg TA2
991266 PDJQHWUROFRP Write in 3 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 745
1 9 9 5 - 2 0 1
51 9 9 5 - 2 0 1
5
20th20th january 2015 | Vol XXI No 1
4 | January 2015
Flow Control Magazine
departmentscolumns6 EDITORrsquoS FILE
4 flow things you need to know aboutthis month
14 APPLICATIONS CORNERa coriolis mass flowmeter providesa better solution
39 WORD SEARCH temperature measurement
40 QUIZ CORNER how to calculate orifice plate flow rate
Cover imagesFlowmetercourtesyEndress+HauserBackgroundiStock
8 NEWS amp NOTES api 624 valveemissions update intelligent features toboost desal pumps market hydraulic fractur-ing water treatment on the rise
34 UP CLOSE with Micro Motionrsquos Model5700 Coriolis Transmitter
35 NEW PRODUCTS
36 WEB RESOURCE FILE
38 ADPRODUCT INDEX
S I N C E 1 9 5 8
Itrsquos More than a Check Valve
Itrsquos a Check-All
When You Need Absolute Precision
CHECK-ALL IS THE ONLY CHOICE
Our spring loaded check valves are assembled
to your exact needs ensuring absolute precision
and reliability They work like they should Plus
most lead times are less than one week Thatrsquos
what makes Check-All the only choice
Get me a Check-AllManufactured in
West Des Moines Iowa USA515-224-2301 bull salescheckallcom bull wwwcheckallcom
Write in 4 or Request Info Ins tantly at wwwFlowControlNetworkcomfreeinfo Write in 5 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
Return on investment calculations for plant upgrade or new
plant construction projects may go through several iterationsbefore the trigger is finally pulled or indeed not pulledldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 845
The new Ultratrade 8c The capability and performance
your market demands
Copyright copy FMC Technologies Inc All Rights Reserved
FMC Technologiesrsquo Ultra 8c ultrasonic owmeter shares the advanced technology
of the next generation Smith Meterreg Ultra Series meters With its touchscreen
interface upgradable memory and high-speed processor the Ultra 8c provides
cutting-edge performance and diagnostic ability And with additional measurement
paths the Ultra 8c has even better cross-ow and swirl compensation for improved
accuracy and repeatability Whether for leak detection or custody transfer theUltra 8c gives you the assurance of superior performance in the eld even for the
most viscous crude oils in todayrsquos market
For more information visit wwwfmctechnologiescomultrafc
wwwfmctechnologiescom
Write in 6 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 945
20 Years of Flow Control This
year marks the 20th Anniversary of
Flow Control magazine Launched
in 1995 with the aim of serving technical
professionals involved with designing oper-
ating and maintaining fluid handling systems in a wide range of
industries Flow Control has leveraged its many years of experi-
ence to establish a unique niche and reputation for providinghigh-quality information to you our subscribers I congratulate everybody who helped
Flow Control get to where it stands today Herersquos to another 20 years of success
Training Time Itrsquos a new year and we have two new
training opportunities for
you to enhance your skillset in 2015
Regular Flow Control columnists Da-
vid W Spitzer and Larry Bachus will
be presenting three-day courses on
Flow Measurement and Pumping
Systems respectively I encourage you and your colleagues to take ad-
vantage of these important training
opportunities For more details see
flwctrlcomflowseminar amp
flwctrlcompumpguy
Oil amp Gas Gender Gap Results of a
new global workforce survey conduct-
ed by OilCareerscom and Air Energi
show a gender gap in the oil amp gas industry
persists despite ongoing efforts to recruit more
women into the industry According to hiring
managers the
top three factors
that significantlycontributed to
the gender gap
in the oil amp gas
industry are
1 A lack of women entering the industry (55
percent)
2 An industry culture created by a male-domi-nated environment (53 percent)
3 The logistics requirement ie travel shift
and working patterns in the field (30 percent)
For more on this story and an infographic seeflwctrlcomog_gendergap
Rockwell Automation Fair 2014 Our colleagueKevin Parker at Processing magazine attended the
annual Rockwell Automation Fair Nov 9-10 in
Anaheim Calif Parker gleaned some interesting perspec-
tive on key trends in process automation including
1 Hardware and software are more blended than ever
2 Fog computing (a kind of cloud computing) is making
headway in industrial engineering environments where latency is a critical concern
For Parkerrsquos full report from the Automation Fair see flwctrlcomrockwellfair2014
DITORrsquoS FILE
6 | January 2015
Flow Control Magazine
4 Flow Things You Need to Know
GROUP PUBLISHERPROCESSINGFLOW CONTROL
MICHAEL C CHRISTIAN | (908) 507-5472mikecgrandviewmediacom
NATIONAL ACCOUNTS MANAGERJIM SEMPLE | (908) 963-3008 jsemplegrandviewmediacom
EXECUTIVE DIRECTOR OF CONTENTMATT MIGLIORE | (610) 828-1711
mattgrandviewmediacom
MANAGING EDITOR AMY W RICHARDSON | (205) 408-5050
arichardsongrandviewmediacom
COLUMNISTS
LARRY BACHUSDAVID W SPITZER JESSE YODER
ART DIRECTORJULIE FLYNN
juliegrandviewmediacom
MANAGER - DIGITAL OPERATIONSMARY BETH ROMANO
SUBSCRIPTION amp REPRINT REQUESTSflowcontrolhalldatacom
Administrative TeamGENERAL MANAGER
BARRY LOVETTE
CHIEF OPERATIONS OFFICERBRENT KIZZIRE
VICE PRESIDENT OF FINANCEBRAD YOUNGBLOOD
VICE PRESSIDENT OF B2B GROUPMIKE WASSON
CHIEF REVENUE OFFICERCHRIS DOLAN
VP AUDIENCE DEVELOPMENTDELICIA POOLE
AUDIENCE DEVELOPMENT MANAGER ANNA HICKS
DIGITAL AUDIENCEDEVELOPMENT ANALYST
STACY BARNES
EDITORIAL ADVISORY BOARDLarry Bachus Bachus Company IncGary Cornell Blacoh Fluid Control
Jeff Jennings Equilibar LLCMitch Johnson JMS SoutheastPeter Kucmas Elster Instromet
Jim Lauria Water Technology Executive
John Merrill PE EagleBurgmann IndustriesSteve Milford Endress+Hauser US Tom OrsquoBanion Emerson Process
Management Micro MotionDavid W Spitzer PE Spitzer and Boyes LLC
Tom Tschanz McIlvaine Company John C Tverberg Metals and Materials
Consulting EngineersJesse Yoder PhD Flow Research Inc
WINNER
WINNER WINNER
PERSPECTIVES FROM THE MONTH THAT WAS IN THE WORLD OF FLOW CONTROL
WINNER WINNER
THE
NETWORK
1
2 3
4
1 9 9 5 - 2 0
1 51 9 9 5
- 2 0 1 5
20th20th
Matt Migliore Executive Director of Content MattGrandViewMediacom
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1045
Endress+Hauser Inc
2350 Endress Place
Greenwood IN 46143
infousendresscom
ww wusendresscom
Sales 888-ENDRESS
Service 800-642-8737
Fax 317-535-8498
Guided wave radar level products - built for safety precision and efficiency
bull Reliable non-contact measurement even for changing process conditions
bull HistoROMreg data management - concept for fast and easy
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bull Multi-Echo Tracking evaluation - highest reliability even with the
presence of obstructions in the vessel
bull Hardware and software developed according to IEC61508 up to SIL3(in homogeneous redundancy)
bull Seamless integration into control or asset management systems
bull Worldrsquos easiest proof test concept for SIL saves time and cost
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The newest generation of Micropilot
Taking your process to the next level
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7232019 Flow Control January 2015
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HE OUTLOOK | News amp Notes
1 ISO15848 ldquoMeasurement test and qualification proce-
dures for fugitive emissionsrdquo
a Part I ndash ldquoClassification system and qualification proce-dures for type testing of valvesrdquo
b Part II ndash ldquoProduction acceptance test of valvesrdquo
2 API 622 ldquoType Testing of Process Valve Packing for Fugitive
Emissionsrdquo
3 End-user defined fugitive emission reduction requirements
Key aspects of valve testing per API 624 include
The standard covers rising and rising-rotating stem
valves up to 24rdquo diameter
Class 1500 valves are not covered
The test medium is methane
310 test cycles are required with three thermal cycles Temperature application range is from -29 C to 538 C
with last cycle 10 cycles user-defined (can be -45 C)
Re-tightening of gland bolts is not permitted during test
Valve stem test orientation is vertical
Several valves must be tested to achieve API 624 com-
pliance Similar industry principles applied to test valves
qualify two nominal sizes smaller one size larger and one
pressure class below
Allowable leakage is 100 PPM maximum
Gate and globe valves need to be tested separately
For example Gate Valves per API602 four tests API600
eight tests (up to 20rdquo diameter) API 603 eight tests andfor Globe Valves per API 602 four tests
Test valves should be production valves not specially
manufactured test valves
As a result of the release of API 624 testing companies have
been gearing up for an increase in the number and size of
test valves and new test houses are coming to market Withthis in mind implementation of API 624 needs to be carefully
monitored and claims from valve manufacturers should be
validated by requesting to view test results Important factors
to be mindful of include
Number of cycles on some valves could be detrimental
to packing as certain smaller size valves donrsquot come with
grease ports to keep the stem lubricated all of the time
Test failures of valve stem threads yokes and glands
Grease traps into packing and causes leakage
At higher temperatures a few greases create volatile
organic compound and burn off
Testing in vertical generates more heat in yoke area
Certain challenges need a good testing company that has
experience in testing on fugitive emissions and provides
guidelines to manufacturers in terms of use of packing valve
grease testing requirements etc
A preliminary survey was conducted with end-users regard-
ing current utilization and application of API 624 For a sum-
mary of responses from this survey visit flwctrlcom1oWijWz
Gobind Khiani PEng is with Fluor Canada Ltd Khiani has
spent 20-plus years in the energy and power business and 10-
plus years in the Western Canadian oil and gas industry Hecan be reached at 403 850-6982 or gobindkhianifluorcom
Valve Standards UpdateEnd-users ramp up compliance efforts for API 624
as new specifications emerge on the horizon
8 | January 2015
Flow Control Magazine
By Gobind Khiani
In the May 2014 issue of Flow Control (page
16) the new standard API 624 ldquoType Testing
of Rising Stem Valves Equipped with Graphite
Packing for Fugitive Emissions First Editionrdquo was
addressed This standard which was published
and put into effect in February 2014 estab-
lishes guidelines for testing industrial valves for
emissions compliance Since the publication ofthe May article further requests from industry
have spurred the creation of another specifi-
cation API 641 ldquoType Testing of Quarter-Turn
Valvesrdquo and an API ldquoPiping and Valvesrdquo commit-
tee has been formed Regulators and end-users
are also working on
1992 1998 2003 2008 2013 2020
4
35
3
25
2
15
1
05
0
M i l l i o n o f
t o n n e s y e a r Will API 624
have a stepeffect in reducing
fugitiveemissions
Global valve fugitive emissions
End User response at best
End User response actual
S O U R C E G O B I N D K
H I A N I
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1245
Intelligent Features to Boost Global WaterDesalination Pumps Market
The Global Water Desalination
Pumps Market is expected to grow
at a CAGR of 77 percent from 2015 to
2019 according to a new report from
TechNavio (wwwtechnaviocom)
The report shows demand for water
treatment has increased significantly in
developing countries where fresh wa-
ter resources can be scarce Providing
clean and potable water to huge popu-
lations has become a priority which is
pushing the demand for water desalina-tion pumps in the market according to
TechNavio
The report emphasizes the emer-
gence of intelligent pump systems as
a major driver of market growth In-
telligent pumps possess the ability to
regulate flow and pressure and these
systems can automatically adjust to
process and pump system changes
ldquoIntelligent pump systems are be-
ing adopted by many manufacturers
because of the high level of fault toler-
ance ability which leads to a significant
reduction in the total cost of owner-
shiprdquo said Faisal Ghaus vice president
of TechNavio in a news release ldquoThe
adoption of these systems will also
help industries comply with current Eu-
ropean Union regulations in relation toreduction in energy consumptionrdquo
The growing demand for clean wa-
ter worldwide will continue to augment
the demand for water desalination sys-
tems which will propel the Global Water
Desalination Pumps Market during the
forecast period
trendlines
wwwflowcontrolnetworkcom January 2015 | 9
Write in 8 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
Intelligent pump sys-tems are being adopt-
ed by many manufac-
turers because of the
high level of fault tol-
erance ability which
leads to a significant
reduction in the total
cost of ownership
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1345
HE OUTLOOK | News amp Notes
10 | January 2015
Flow Control Magazine
Hydraulic Fracturing WaterTreatment amp Reuse Expected to Soar
Wastewater treatment spending for
hydraulic fracturing is expected to
grow almost three-fold from $138 mil-
lion in 2014 to $357 million in 2020 in
the US according to a new report from
Bluefield Research
The US hydraulic fracturing industry
consumes over 1 billion barrels of wa-
ter annually producing 450ndash500 mil-
lion barrels of contaminated water for
disposal with only about 14 percent
treated and reused Bluefield cites watersupplies increasingly at risk tighter regu-
lations emerging in key states and costs
of disposal on the rise as factors con-
tributing to the substantial rise in water
treatment and reuse which is expected
to account for 27 percent of total pro-
duced and flowback water by 2020
Overall the US hydraulic fracturing
industry will spend $638 billion in 2014
on water management Water transport
and disposal costs will account for 66
percent of the total water managementspent this year with treatment compris-
ing roughly 2 percent
Bluefield reports water scarcity in
Western US states has had little im-
pact to date on fracturing water supply
but that is likely to change if droughts
persist Meanwhile state regulators are
beginning to tighten control of produced
water disposal In Pennsylvania where
policymakers in 2010 placed discharge
limits on wastewater from unconven-
tional oil amp gas operations statewide
treatment and reuse rates for the Mar-
cellus jumped to 90 percent in 2014
The increasing cost of transport and
injecting water into wells mdash now ac-
counting for 66 percent of water servicesspending mdash and the improving cost
structures of treatment provide another
driver of reuse Bluefield reports Well
operators that employ treatment and re-
use solutions spend on average $880
per barrel of water used compared to
$1020 per barrel of water trucked and
injected into wells although cost com-
parisons are site specific
ldquoFracking has been the Wild West for
the US water industryrdquo said Reese Tis-
dale president of Bluefield Research ina prepared statement ldquoThere are three
reasons for this first there has been
an explosive build-out of fracking well
installations now surpassing 126000
Second there has been a lack of clear
regulation on water management in key
markets And third there is not a one-
size-fits-all treatment solution for frack-
ing meaning solutions providers have
had to ascend a steep learning curve
to treat the variable wastewaters that a
single well is capable of producingrdquo
Tisdale notes that these inhibitors
while still acute are beginning to take on
a new form This is partially due to signifi-
cant gains in water management experi-
ence realized adoption of more efficientwater management strategies among
well operators and the emergence of
new policy mechanisms from regulators
that are playing catch-up with the fast-
moving hydraulic fracturing industry
trendlines
Treatment2
Disposal
6
Supply10
Storage22
Transport60
US $638Billion
S O U R C E B L U E F I E L D R
E S E A R C H
Write in 23 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
Industry-Leading
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Temperature Measurement Solutions
bull Probe type industrial RTDsbull Electronic temperature switchtransmitter bull Vapor-actuated remote thermometersbull Digital temperature indicatorsbull Platinum resistance temperature transmitterbull Compact OEM temperature transmitter bull Industrial amp instrument type bimetal thermometersbull Thermowells
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1445
New Technique Could ReduceEnergy Required for Oil Refinement
UK scientists have developed a
technique they say has the poten-
tial to dramatically reduce the amount
of energy required for the refinement
of crude oil
Professor Martin Schroumlder and Dr
Sihai Yang from The University of Not-
tingham (wwwnottinghamacuk ) have
led a multi-disciplinary team of scien-
tists from Nottingham the Science and
Technology Facilities Councilrsquos (STFC)
ISIS Neutron Facility Oak Ridge Na-tional Laboratory and Diamond Light
Source to discover a porous material
that works like a chemical sponge to
separate a number of important gases
from mixtures generated during crude
oil refinement
According to a news release from
The University of Nottingham the ex-
isting industrial process uses ldquohuge
amounts of energy to separate and pu-
rify these gases so the new technique
has the potential to revolutionize the oil
industry by significantly reducing car-
bon emissions and making the process
more environmentally friendlyrdquo
Commercially UsefulCrude oil is a raw material that is
refined to produce fuel for cars toheat homes and to create polymers
and other useful materials It is made
up of a complex mixture of hydro-
carbons (chemical compounds that
contain only hydrogen and carbon) of
which certain components are espe-
cially commercially useful
One industrial process used to
achieve hydrocarbon separation is
called ldquocryogenic distillationrdquo which is
widely used worldwide and uses vast
amounts of energy to generate the high
pressures and cryogenic temperatures
required to ensure efficient separation
research amp development
wwwflowcontrolnetworkcom January 2015 | 11
PLASTIC CONTROL VALVES FORALL YOUR CORROSIVE APPLICATIONS
PO Box 938 bull Angleton TX 77516Tel (979) 849-8266 bull wwwcollinsinstcom
Collins plastic control valves are
highly responsive control valves
designed for use with corrosive
media andor corrosive atmos-
pheres
Collins valves feature all-plastic
construction with bodies in PVDF
PP PVC and Halar in various body
styles from 12 - 2 with Globe
Angle or Corner configurations and
many trim sizes and materials
Valves may be furnished without
positioner for ON-OFF applications
Call for more information on our
plastic control valves
Write in 9 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1545
of hydrocarbon mixtures into pure components
However researchers say an innovative solution may
have come in the form of a novel chemical sponge This
porous material a metal-organic framework was devel-
oped by the same team at Nottingham just two years ago
Now in research published in Nature Chemistry for the
first time scientists have proven that it can be used toseparate hydrocarbon mixtures without the need for high
process pressures or very low process temperatures
Reusable MaterialsMade from cheap organic materials aluminum nitrate
salt and water the porous material called NOTT-300 is
able to adsorb different gases found in mixtures of hydro-
carbons at different rates making it possible to sepa-
rate them and extract the most useful ones NOTT-300
requires less energy to function than existing methods
as it operates at ambient temperatures and normal pres-
sures researchers say The gases that are adsorbed intoNOTT-300 can be removed without a significant energy
input and therefore the material can be easily reused
The team of scientists from Nottingham used Diamond
the UKrsquos synchrotron science facility as well as STFCrsquos
ISIS Neutron Facility and Oak Ridge National Laboratory
the UKrsquos and USArsquos world-leading neutron facilities re-
spectively to prove that the sponge works under real-life
conditions
Professor Martin Schroumlder Dean of the Faculty of Sci-
ence at Nottingham said in the news release ldquoIt is a very
important to be able to separate different hydrocarbons ef-
fectively and efficiently with low-energy consumption Po-rous solids such as the metal-organic framework system
studied here represent important materials for the future
development of low-energy separation technologies We
are most grateful to our collaborators at ISIS Neutron Fa-
cility Oak Ridge National Laboratory and Diamond Light
Source in bringing this work to fruitionrdquo
Significant Impact on Oil IndustryDr Sihai Yang the winner of Diamond Young Scientist
and BTM Willis Prize is a Senior Research Fellow at
Nottingham He led the project together with Professor
Martin Schroumlder Yang said ldquoWith the help of advancedcentral facilities like Diamond ISIS and ORNL we have
developed a new separation technique which can poten-
tially reduce the energy usage associated with oil petro-
leum and chemical industries which require the separa-
tion of raw hydrocarbons from crude oil
The discovery of the new material NOTT-300 could
have a significant impact on the oil industry by removing
the necessity for some energy-intensive refinement pro-
cesses researchers say
The research was funded by Engineering and Physical
Sciences Research Council (EPSRC) the European Re-
search Council (ERC) The University of Nottingham andLeverhulme Trust
12 | January 2015
Flow Control Magazine
Write in 21 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
No media contact - No risk of leaks
No process Shut-Downs for installation
No bypass needed
For hazardous area locations (FM approved)
Monitor your Total Acid Consumption
Increase your Plant Up-Time
Balance your Processes
PIOXreg S
PIOXreg S - the evolution of flow and concen-
tration measurement in acid production
Non-intrusive mass flow concen-
tration and density measurement
of aggressive media
wwwpiox-scom
wwwfleximcom
Contact us for a free trial measurement
Thank you for your votes and
making PIOXreg S a Flow Control
Awards Winner
THE OUTLOOK | News amp Notes
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1645
The ASCO trademark is registered in the US and other countries The Emerson logo is a trademark and service mark of Emerson Electric Co copy 2014 ASCO Valve Inc
1-800-972-ASCO (2726) | e-mail info-valveascocom | wwwascovalvecomSpoolValve
Now get spool valves with industry-leading ASCO solenoid technology built in
Delivering unmatched performance and durability our compact new valves are
perfect fits for all your onshore near-shore or offshore upstream control panels A
range of easily configured features and options includes superior temperature and
pressure ratings plus low-power models The industryrsquos toughest testing ensures
every rugged stainless steel valve meets or exceeds specifications Plus we design
and support every spool valve we make Ask for ASCO the ultra-reliable choice for oil
and gas control panels
These new spool valves will fit right in
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 174514 | January 2015 Flow Control Magazine
PPLICATIONS CORNER | Process Instrumentation
This is the final article in a series based on the troubleshoot-
ing of a mysterious unit shutdown due to flowmeter perfor-
mance problems
If yoursquove followed this column for most of 2014 you know
that what should have been a liquid ammonia stream to the
feed plant became problematic due to the occurrence of
bubbles of ammonia gas These bubbles caused an ultrasonic
flowmeter in a unit to indicate zero flow and caused the reactor
to scram (shut down) under warm operating conditions The source of the bubbles was traced back to the pres-
sure drop associated with a control valve located at the
exit of the liquid ammonia tank farm
This issue was resolved by identifying the problem
and fixing it at its source This was a pragmatic ap-
proach at the time (early 1980s) given the operation
of the cooling system in the unit and the limited selec-
tion of applicable flowmeter technologies
By the early 1990s changes were implemented that elim-
inated all process cooling requirementsmdashexcept for the small
jacketed cooler upstream of the liquid ammonia flowmeter In
other words after these changes the entire cooling system
would be operated and maintained to cool a few meters of
one small ammonia pipe Coincidently at about the same
time Coriolis mass flowmeters became more mature and
could reasonably measure the mass flow of liquid streams
with homogeneous low levels of vapor
The convergence of these two events resulted in another
approach to the problem that was not available in the early
1980smdashie install a Coriolis flowmeter that could operate in
the presence of bubbles The purchase and installation of a
Coriolis mass flowmeter was given high priority given its im-pact on unit operation economics and safety (by eliminating
the ldquomidget-makerrdquo (see March 2014 page 14))
Plant requirements and the technology that can meet
plant needs keep changing An excellent solution today can
become outdated in just a few years However there are few
substitutes for understanding fundamentals when addressing
a problem In other words there can be more than one way
to skin a cat FC
wwwspitzerandboyescom
Problem Solved AgainA Coriolis mass flowmeter provides a better solution
F o r B e t t e r P i p i ng S y s t e m P e r f o r m a nc e hellipFor Better Piping System Performancehellip
I d e a l f o r Ag g r e s s i v e C h e m i c a l s
1384 POMPTON AVENUE CEDAR GROVE NEW JERSEY 07009
973-256-3000 bull Fax 973-256-4745www p l as t om a t ic co m bull i n f o p la s t om a t ic co m
bull Rugged thermoplasticshandle corrosive andultra-pure chemicaltreatments
bull Constant pressure enhances
pump performancebull Prevents overpressure in
piping system
bull Wide range of pressuresettings
bull PTFE shaft and diaphragm designs
bull 1 4rdquo - 3rdquo sizes in PVC CPVC PVDFPolypro and PTFE
bull First State approved
thermoplastic valve for
anti-siphon applications
Write in 10 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
David W Spitzer
Ammonia Gas | Coriolis Flowmeter | David W Spitzer | Scram | Troubleshooting
FLOWSTREAM Find related content flowcontrolnetworkcom
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and Boyes
LLC offering engineering seminars strategic marketingconsulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer can be reached at 845 623-
1830 or at wwwspitzerandboyescom
The purchase and installation of a
Coriolis mass flowmeter was given
high priority given its impact on unit
operation economics and safetyldquordquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1845
Smart Valve Positioner
Beyond Control The NEW Research Controlreg SRD positioner does
everything you expect any valve positioner to do
plus more The SRDrsquos comprehensive diagnostics tool
continuously monitors for fugitive emissions delivers
real-time performance statistics and facilitates both
proactive and reactive process management Available
with integrated network communications the SRD is
compatible with Research Control valves and most other
pneumatically-actuated valves
Visit wwwbadgermetercomSmart-Valve-Positioners or
call 877-243-1010 for more information today
copy 2015 Badger Meter Inc
RESEARCH CONTROL is a registered trademark of Badger Meter Inc
Write in 11 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1945
Process improvements to increase yield or cut manufactur-
ing costs typically require enhanced process control but the
installed base of measurement instrumentation in a process
plant may simply be unable to facilitate improvements because
of age inadequate performance or unreliability Maintenance
cost and unscheduled process downtime for an aging process
plant can be very damaging to the balance sheet Upgrading
to new more accurate and more reliable instrumentation can
be prohibitively expensive New plant construction must alsomaintain a focus on optimizing costs for the process control
infrastructure The budget approval decision for new plant
construction must weigh such costs against projected market
conditions for the products that the plant is intended to manu-facture In todayrsquos volatile global marketplace return on invest-
ment calculations for plant upgrade or new plant construction
projects may go through several iterations before the trigger is
finally pulled or indeed not pulled
This article describes advances in two-wire instrumenta-
tion specifically in relation to flowmeters that have taken
place in the past few years and the significant cost benefits
that this new technology can realize for plant builders and op-
erators in terms of capital investment and cost of ownership
The Significance of Two-Wire Loop Power
A survey involving 204 participants in the chemical indus-try across Germany Switzerland the UK Canada and the
United States (Manfred Koenig PhD KIM Ludwigshafen
Germany 2006) revealed an 87 percent preference for two-
wire instrumentation versus four-wire in process applications
and 89 percent for utilities This overwhelming preference
may stem from the fact that older process plants were built
with two-wire twisted-pair cable networks connecting all
process units and measuring instruments together in an
overall plant control scheme
However these existing cables are relatively unsophisti-
cated and incapable of supporting anything but low-energy
instrumentation that is insensitive to interference from otherelectrical sources that might be sharing the same cable con-
duit Further the low energy levels supported by these two-
wire loops are more easily rendered safe in terms of explo-
sive risk in hazardous areas containing flammable materials
Many older process plants are also likely to have a significant
installed base of flowmeters employing pre-war (pre-1945)
technology such as positive displacement (PD) turbine vari-
able area (VA or Rotameter) and differential pressure (dP)
Market data firm Flow Research Inc (wwwflowresearch
com) indicates collectively a future compound negative annual
growth rate approaching minus 3 percent to 5 percent for PD
turbine and VA flowmeter types while dP is expected to keeppace with market growth (World Market for Flowmeters 2010)
YSTEMS DESIGN | Flow Measurement
16 | January 2015
Flow Control Magazine
The Two-Wire
ADVANTAGENew wiring options enable modern instrumentsto drive cost savings in existing plant systems
By Steve Milford
Advances in two-wire instrumentation have enabled mod- ern technology to be employed to the advantage of older
plant and process systems
Some chemical manufacturing plants are
competing for survival not only externally
against other global companies but also
internally among the global facilities of theirown company Other industry sectors face
similar challenges
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2045wwwflowcontrolnetworkcom January 2015 | 17
The Need to Replace Older TechnologiesUntil the 21st century two-wire loops were only able
to support these relatively unsophisticated instruments
which convert their measurement by various means into a
4-20mA output or pulse signal to the control system The
more advanced post-war flowmeter technologies such as
Coriolis ultrasonic or electromagnetic flowmeters have
until just eight years ago required a dedicated power sup-
ply for their function in addition to the output loop and
thus a four-wire infrastructure was required as a minimum
Therefore upgrading older two-wire meter devices to moremodern four-wire technology could require significant
expenditure in terms of the installation of separate power
cables and supply modules
There was a major breakthrough in 2006 when a true
two-wire loop-powered inline liquid ultrasonic flowmeter
was introduced (Figure 1) The nature of this breakthrough
was innovation in device power management This was the
missing piece up to that point because to be a true loop-
powered device the meter had to directly provide a full 16
mA span using less than 36 mA of remaining loop current
and less than 1 Watt of electrical energy The flowmeter
operated on a single 4-20 mA HART two-wire loop wasremotely powered by a DC supply was certified Class 1 Divi-
sion 1 and could be deployed as Intrinsically Safe through
the use of an approved safety barrier
A true two-wire loop-powered Coriolis flowmeter followed
in 2011 (Figure 2) employing a new and more advanced
common electronics platform A two-wire loop-powered inline
ultrasonic flowmeter for low-pressure gas was introduced in
2012 and a second two-wire loop-powered Coriolis meter fol-
lowed in 2013 offering improved measurement performance
and an additional high-performance meter tube material
Electromagnetic and vortex flowmeters had already been
available for some years in two-wire loop-powered form butimproved performance resulted as these designs were incor-
COURTESYENDRESS+HAUSER
Figure 1 A two-wire ultrasonic flow- meter released in 2006 operated ona single 4-20 mA two-wire loop
Write in 12 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
omegacom
reg
I I I I LL I
I I I I LL I
copy COPYRIGHT 2015 OMEGA ENGINEERING INC ALL RIGHTS RESERVED
1-888-826-6342
Prices listed are those in effect at the time of publication and are subject to change without noticePlease contact OMEGArsquos sales department for current prices
FPD3000 SeriesStarts at$630
FPD3300 SeriesStarts at
$790
Visit omegacomfpd3000
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OSXL-TIM3$999
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Positive Displacement Flow Meterfor Fuels and Oils
bull Aluminum Bodybull FKM Sealsbull Temperatures up to
80ordmC (176ordmF)bull NPT or BSP Threadsbull DIN JIS or ANSI
Connection (Availableon 1 and Larger Sizes)
Positive DisplacementFlow Meter for Solvents
Thermal Imaging CameraFor Inspection andFactory Diagnosis
Note Not for ExportUSA Only
Your One-StopSource for Process
Measurement and Control
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 214518 | January 2015
Flow Control Magazine
porated into their new common electron-
ics platform in 2013 So all the ldquomodernrdquo
flow measurement technologies mdash that
is to say those introduced post-war mdash
have become available as two-wire loop-
powered devices with one exception
namely thermal mass (thermal disper-
sion) meters Unfortunately the power
requirements for this technology exceed
what is currently deemed possible withtwo-wire loop-power management
Payback forTechnology UpgradeConsider a 1rdquo process line
containing a liquid process
ingredient costing $1lb at a
mass flowrate of 150 lbmin-
ute We have $150minute
flowing in the line translating
to $9000hour and $72000
per eight-hour shift That cal-culates further to $360000
per five-day working week and
for a working year of 40 weeks for
example that is $144 million Assume
the existing device is a turbine flowmeter
Now imagine a two-wire loop-
powered Coriolis mass flowmeter is
installed in place of the existing meter
The line would need to be drained and
probably one process flange replaced
allowing the Coriolis to fit mechanically
in place of the turbine However thetwo-wire loop already used for carrying
the existing meterrsquos flow signal to the
control room can be used unaltered
for the complete electrical installation
aspects of the Coriolis flowmeter
The upside of the change is signifi-
cant and clear cut Assuming the exist-
ing meter measurement uncertainty was02 percent of reading then measure-
ment uncertainty improves through use
of Coriolis to 01 percent of reading
giving a 01100 x $14400000 im-
provement in control of the ingredient
annually or $14400 A two-wire Coriolis
mass flowmeter with 01 percent mass
flow accuracy would be paid for in ap-
proximately 6-8 months In practice the
improvement in measurement uncer-
tainty would be greater as the operator
would gain temperature and density in-formation from the Coriolis and the mea-
surement would be devoid of any fluid
property dependence Viscosity change
for example can have a major impact on
turbine meter performance Mechanical
wear and tear that turbine meters even-
tually experience which causes them to
under-register flow is precluded by mod-
ern devices like Coriolis
Furthermore if the process ingredient
was being blended with another then ad-
ditional process improvements could berealized through in-line blending control
using Coriolis technology for final density
as the control point It is possible to have
dual 4-20 mA outputs from two-wire
loop-powered meters but as the main
4-20 mA output representing the prima-
ry variable is also HART then an external
HART Loop Converter or HART IO card in
the control system can provide second-
ary tertiary and quaternary variables as
4-20 mA signals A Coriolis meter is trulya multi-variable device Certain two-wire
devices are also available with Profibus
or Foundation Fieldbus communication
Cutting Wiring CostsIn 2003 WIBEXERA (International
Instrument Usersrsquo Associations) Report
T 2732 X 03 was published and it pro- vided an average survey of prices quoted
in projects at that time for the provision
of power supplies for four-wire instru-
ments The price ranged from euro1200
to euro1800 per instrument depending
upon design and plant characteristics
for an average cost of euro1500 (about
$2000) It would be reasonable to
assume an inflationary factor of 2 per-
cent per annum giving an approximate
current-day figure of $2500
From another source within thechemical industry an estimation of
$40foot to $50foot was given for in-
stallation of four-wire cabling For a
linear 50-foot cable run with for ex-
ample a 10-foot vertical at each end
this equates to $3150 Actual costs
and budget estimates have been given
as high as $10000
The Extent of the Opportunity The modern post-war flow measure-
ment technologies have different powerrequirements and consequently they
are not all available for the
same size range in two-wire
loop-power form For example
two-wire Coriolis flowmeters
are limited to 2rdquo diameter
electromagnetic and inline
low-pressure gas ultrasonics
are limited to 8rdquo and vortex
and inline liquid ultrasonic are
limited to 12rdquo
Nevertheless for thechemical industry in particu-
lar perhaps two-thirds of the
process pipes in a plant will be no larger
than 2rdquo and even when the host process
pipe is larger a correctly sized flowmeter
can still be less than 2rdquo There is consid-
erable scope for two-wire loop-power to
deliver value for flow measurement ap-
plications with total safety
The virtues of Coriolis technology
have been covered but what about
other two-wire technologies An elec-tromagnetic flowmeter in two-wire form
YSTEMS DESIGN | Flow Measurement
In todayrsquos volatile global mar-
ketplace return on investment
calculations for plant upgrade or
new plant construction projects
may go through several itera-
tions before the trigger is finally
pulled or indeed not pulled
ldquo
rdquo
COURTESYENDRESS+HAUSER
Figure 2 Two-wire Coriolis flowme- ters became available in 2011
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2245
can be used on water wastewater or
a light water-based slurry provided the
fluid has around a 20 microSeimenscenti-
metre (microScm) electrical conductivity
A magnetic flowmeter is full bore un-
less flowrates dictate a reduced meter
size in the interests of performance and
so there are no intrusions into the flow
stream and no pressure loss An accu-
racy of 05 percent of reading is normal
from a two-wire magnetic meter and a
modest five diameters (5D) of straight in-let run is needed to avoid error from up-
stream flow disturbances When the fluid
exhibits insufficient conductivity then
the same performance and installation
requirements can be met by an inline ul-
trasonic flowmeter provided the liquid is
essentially clean and bubble-free
For gas or steam applications a vor-
tex meter is the normal choice Using a
built-in temperature sensor a two-wire
loop-powered vortex meter can calculate
mass flow of saturated steam using in-ternal steam tables An external pressure
input allows mass flow of steam to be ac-
curately calculated even when saturated
steam becomes superheated as can oc-
cur downstream of a pressure regulating
valve With mass flow known the vortex
meter can calculate energy and heat flow
A new and exciting development is
the ability of the vortex meter to indicate
wet steam and calculate dryness frac-
tion or steam quality For safety and ef-
ficiency saturated steam should be dry
and free from condensate that is to say
it should possess a high steam quality
factor However the dry or wet state of
saturated steam can sit on a knife-edge
and shift to the opposing state due to
the slightest change in process condi-
tions Rapid and reliable indication of
this change of state is now available
Perhaps the most astonishingachievement in the power management
of two-wire loop-power flowmeters is
that of the ultrasonic biogas meter It is
now possible not only to measure the
flow of wet dirty variable composition
and low-pressure anaerobic digester
gas landfill gas and coal bed methane
gas with a two-wire loop-powered ultra-
sonic flowmeter but also the same de-
vice uses an inbuilt temperature sensor
in combination with measured sound
velocity to calculate methane contentcalorific value and energy flow
Technology to Take UsForwardModern flow technologies provide instru-
ment engineers with vital self-monitoring
information The format of such infor-
mation is easier to understand and act
upon when presented in accordance
with harmonized international guidelines
for online plant asset management eg
NAMUR Standard 107
Continuous plain-text self-diagnostic
and process-related information with
suggested remedies (Figure 3) make it
possible for instrument engineers andoperators to take action at the appro-
priate time mdash immediately or during
the next scheduled shutdown mdash saving
time and money by knowing the exact
health of their measuring point and the
probable actions required to rectify any
abnormal conditions Device verifica-
tion offering third-party validated trace-
ability can be performed on demand ei-
ther locally or remotely from the control
room without the expense of a man in
the field Calibration is then avoided ordeferred without process interruption
Where a process plant has a large
installed base of older mechanical tech-
nologies the decision to embark upon a
program of replacement for plant mod-
ernization cannot of course be taken
easily There are the stocks of spare
parts to consider along with the plant
instrument technicians who are trained
on and at ease with the old devices
However a process plant that retains
the older technology going forward willbe at risk and may find it increasingly
difficult or even impossible to maintain
a cost position that competes effective-
ly in the global market FC
wwwusendresscom
wwwflowcontrolnetworkcom January 2015 | 19
Steve Milford
is a Flow Product
Business Manager
for Endress+Hauser
Inc in Greenwood
Ind He has been
involved in flow
measurement since
1983 and has been
actively involved with standards devel-
opment for flow technology within the
International Standards Organization
(ISO) and the British Standards
Institute Mr Milford can be reached
at stevemilfordusendresscom
Steve Milford
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Coriolis Flowmeter | Magnetic Flowmeter | Two-Wire | Ultrasonic Flowmeter | Vortex Flowmeter
Figure 3 A modern instrumentrsquos display module can provide continuous plain- text self-diagnostic and process-related information
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2345
The bottom line is the volume of gas under one set of
pressure and temperature conditions is not the same as it
would be for the gas under different conditions Why is thisimportant Without compensation for compressibility read-
ings taken by gas flowmeters can result in measurementsmdash
and costs to the buyermdashsignificantly lower or higher than they
should be
The flow of gas in a system can be accounted for and
reported in a number of ways such as by volume by mass
flowrate and by energy Inline turbine meters can offer both
reliability and accuracy in measuring gas flow when matched
with a monitor capable of calculating and displaying results
that have been adjusted for the nature of the gas and impor-
tantly the pressure and temperature
Measuring Flow with an Inline TurbineFlowmeter
With an inline turbine meter gas flows into the meter through
a length of piping that helps to pre-condition the flow by
reducing undesirable swirls and asymmetry Where consid-
ered necessary a flow straightener may even be installed in
line to create a uniform flow profile to the extent possible
As can be seen in Figure 1 a rotor support within the tur-
bine housing further conditions the flow and directs it through
the blades of the rotor High-precision ball bearings allow the
rotor to freely rotate on the shaft
The rotorrsquos rotational speed is directly proportional to the velocity of the fluid passing through the meter The rotor itself
incorporates magnets (or magnetic blades depending on thedesign) while the housing is non-magnetic
A proximity sensor (also known as a pickup coil) is located
in line with the rotor and detects the electrical pulses gener-
ated by the ferrous rotor spinning through the magnetic field
Each pulse represents a discrete volume of gas The out-
put frequency provides the indication of the gas flow rate and
the accumulated pulses over a specified time represent the
total volume of fluid for that measurement period
Need for Calibration The flowrate of the gas through the meter cannot be deter-
mined accurately unless the meter is calibrated The fac-tory calibration determines the meterrsquos constant known
as a K-factor which is then inputted into the gas monitor
PPLICATION NOTES | Flow Measurement
20 | January 2015
Flow Control Magazine
COMPENSATING for
Compressibility inMeasuring Gas Flow Why K-factor adjustment is essential foraccurate inline turbine flow measurement
Unlike crude oil and other liquid fossilfuels natural gas poses a challenge
in monitoring the quantity of gas flowing
through pipelines While liquids do not com-
press gases do and the mass flowrate of
gas being transmitted through gathering
lines depends on both the pressure and
temperature
By Kevin Clark
Figure 1 Internal components of a liquid turbine flowmeter
C O U R T E S Y
T U R B I N E S
I N C
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2445
Wondering Whether the
Pump Guy Seminar
Is for YouCheck out the ldquoPump Guy Insightsrdquo
video series flwctrlcompginsights
PUMP GUY INSIGHT 1NPSHa vs NPSHrmdashWhy all pumps need gauges
PUMP GUY INSIGHT 3How to Operate Your Pump at Best Efficiency
PUMP GUY INSIGHT 5Head vs Flow
PUMP GUY INSIGHT 2 Your Pumps Are Constantly Moving On Their Curves
PUMP GUY INSIGHT 4 The Role of the Pump Reliability Chain
PUMP GUY INSIGHT 6How to Read a Pump Curve
PARTNER SPONSORSFor more information and to register
for upcoming Pump Guy Seminars
visit FlowControlNetworkcomPumpGuy
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2545
PPLICATION NOTES | Flow Measurement
22 | January 2015
Flow Control Magazine
Gas flowmeters measure the actual volume of gas passing
through the meter per minute irrespective of pressure and
temperature1
The volumetric flowrate of a gas is often corrected to
ldquostandardizedrdquo conditions of pressure and temperature While
ldquostandardrdquo conditions can vary depending on the definition
in the US this typically means a pressure of 1473 PSIA(pounds per square inch absolute) and a temperature of 60 F
The flowrate measurement is reported in standard cubic feet
per minute (SCFM)
Compensating for changes in pressure and temperature is
critical Consider a meter system setup for flowing conditions
of 60 PSIG (pounds per square inch gauge) and 60 F and the
line pressure decreases to 50 PSIG while the temperature
remains constant The difference in SCFM between the two
is more than 15 percent which would cost the buyer more
for the gas than it should As Table 1 demonstrates even a
small variation in pressure will result in a surprisingly high er-
ror percentage
Automation of the K-Factor The K-factor is established by an initial factory calibration In
the case of a non-compensated flow monitor any variations
in pressure and temperature will result in manual adjust-
ments needed to the K-factor In order to maintain accurate
flow measurement users must monitor pressure and temper-
ature and make corresponding adjustments to the K-factor To eliminate these manual adjustments some suppliers offer
a flow monitor that automatically adjusts for any changes in
pressure and temperature
These monitors provide accurate flow measurement regard-
less of changing environmental conditions in some cases sup-
porting applications with pressures as high as 15000 PSIG and
temperatures between -350 F to 350 F with a standard accura-
cy of +-1 percent over a flow range of 05 ACFM to 650 ACFM
Final NotesDuring the operation of a flowmeter system the ability to obtain
a readout mdash and to adjust for line pressure and temperaturechanges mdash is sometimes compromised by a lack of electric
power This issue is especially true along gas pipelines in remote
areas To overcome this limitation some manufacturers have
designed low-powered flow monitors which can operate for up
to on year on a single lithium D-cell battery
It is important for users to recognize the effects of the
compressibility of gas As such the quantity of a gas flow-
ing through a gas flowmeter depends on the pressure and
temperature In order to ensure accuracy any flowmetering
system must employ a means to correct for these effects
Otherwise the readout is certain to be in error and could be
unnecessarily costing money This is particularly crucial onwellhead production and in billing scenarios FC
wwwturbinesincorporatedcom
Notations1 The measurement factor in the US is known as the
ACFM actual cubic feet per minute (Metric units are typically
ACMH actual cubic meters per hour)
Table 1 Error induced by line pressure changes
Constant Temperature with Varying Pressure
Pressure Temperature PulsesSCF Error
50 60 2556027821 1546
51 60 2517123288 1370
52 60 2479385307 1199
53 60 2442762186 1034
54 60 240720524 873
55 60 237266858 717
56 60 2339108911 566
57 60 2306485356 418
58 60 2274759285 275
59 60 2243894166 136
60 60 2213855422 000
61 60 2184610304 132
62 60 2156127771 261
63 60 2128378378 386
64 60 210133418 508
65 60 2074968632 627
66 60 2049256506 743
67 60 2024173807 857
68 60 1999697703 967
69 60 1975806452 1075
70 60 1952479339 1181 Flow Measurement | K-Factor | Measurement
Accuracy | Turbine Flowmeter
Find related content flowcontrolnetworkcomhellipSearch on
FLOWSTREAM
Kevin Clark is senior develop-
ment engineer for Turbines Research
amp Development LLC Turbine RampD is a
subsidiary and the research and techni-
cal support arm of Turbines Inc which
serves a range of industries and applica-
tions from oil amp gas to cryogenic liquids
to custody transferKevin Clark
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2645
Pumps Bearings amp Seals TECHNOLOGY REPORT
FEATURES
SYSTEMS DESIGN
The ComplicatedCase of
Compressors
withSide-Streams
24 28 32BEST PRACTICES
How PumpingSystems
AffectSealing
Performance
TECH OUTLOOK
BearingSuppliers
Drive Gains InDeveloping
Markets
wwwflowcontrolnetworkcom January 2015 | 23
S P E C I AL S E C T I O N
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2745
The design and operation of compressors with side-
streams has always been difficult because flow entering the
compressor needs to be mixed with the core flow already
in the compressor (compressed in section-1) in a manner
that does not degrade the aerodynamic performance of sur-
rounding sections Minimizing losses and ensuring proper
mixing of the side-stream flow and core-flow are required to
ensure effective performance of a compressor of this sort
Key considerations for an application involving compres-
sors with side-stream flow include
The plant process typically dictates the side-stream
flange pressure
The impellers upstream of the side-stream should
achieve the necessary pressure for the core-flow
The side-stream flow is typically at a temperature dif-
ferent from compressor core-flow temperature
Process plants need some degree of operational flex-
ibility ie the ability to support variations in core-flow condi-
tions and side-stream conditions
Modern process plants are usually specifying more than
one operating conditions (sometimes two or more manda-
tory conditions) which can present challenges to compres-
sors with side-streams Adding to these issues modern
compressors should operate with much higher impeller tip
The COMPLICATED CASE ofCompressors with Side-StreamsConsidering key system design requirements
to ensure operational efficiency By Amin Almasi
4 January 2015
Flow Control Magazine
|
y
g
Some compressors in certain applications
have one or more incoming side-streams
(or side-loads) that introduce side-stream
flow to mix with the core flow In other words
a radial side-stream inlet is utilized in multi-
impeller centrifugal compressors to introduce
additional gas into the mid-stage of a com-
pressor This design enables optimization in
some process plants However the flow dis-
tribution after the junction of the side-stream
and the main return channel of the upstream
section can significantly affect the perfor-mance of the next section of compressor
In most cases the pressure levels at these
side-streams should be accurately predicted
to meet the theoretical performance
Compressor station at a natural gas processing plant
R U D M E R Z W E R V E R I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2845
speeds and inlet Mach numbers compared to previous
generations of compressor technology
Likewise side-streams are now com-
monly used with medium-sized and
large-sized compressors (eg 1ndash60
MW) The costs associated with cor-
rections on side-stream compres-
sor applicationsmdashany repair
inefficient operation and power
lossesmdashwould be very high Fur-
ther compressors with side-streams
are usually sensitive and difficult
machines to operate In particular
performance curves (performance
pressures efficiency etc) are sen-
sitive to suction inlet conditionsside-stream inlet conditions vol-
ume flow ratio (side-stream vol-
ume to core-flow volume) and side-stream losses
Compressors with side-stream often perform far below
expectations The main reason is that side-stream compres-
sors are different than conventional compressors (without
a side-stream) in design and operation For a compressor
with side-streams tighter tolerances in operating conditions
must be identified and applied Uncontrolled variations of
suction pressure or side-stream pressure are major prob-
lems Another major issue is the variations of the flow ratio
(side-stream flow to core-flow)
Compressor Side-Stream amp Mixing SectionIn many centrifugal compressors the portion of the side-
stream system from the flange connection to the mixing
section is similar to a compressor inlet A great challenge
is ensuring the mixing section provides circumferentially
uniform merged-flow with minimum losses This can be
achieved via effective design of the inlet configuration and
mixing section of the side-stream compressor such that
the impeller can be maintained over the whole operating
range of the compressor In many cases while there are
mixing sections provided for the machine the flows do not
completely mix before entering the impeller of the section-2
(the impeller after the mixing section) Non-uniformity at
inlet flow to the impeller is a key concern for compressor
performance
Another consideration is a compact design of the side-
stream mixing section Specifically a mixing section with
less axial length is always preferred This axial length can af-
fect the compressor rotor dynam-
ics the rotor length and over-
all compressor performance
(design cost operation and
reliability)
The side-stream exit pressure
(side-stream pressure at inlet
of the mixing section) is mainly
a function of the side-stream
flow velocity and the pres-
sure in the previous section of
the compressor Conversely the side-
stream flange pressure can depend on
side-stream flow velocity and section-1
exit conditions Therefore the side-stream
inlet flange volume flow is a function of theflange pressure compressibility (at that
pressure and temperature) and mass flow
Some engineers assume that the side-stream flange pres-
sure is equal to the inlet pressure of the first impeller of the
section-2 This is not true The mixed total pressure can be
estimated on a mass-averaged basis using side-stream total
pressure and return channel exit (section-1) total pressure
In some designs because of the lower static pressure at
the side-stream exit the total pressure at the return channel
exit is lower even though the velocity upstream is roughly
matched for both streams The pressure usually increased
at the returned channel but it can be reduced again at the
side-stream exit While simple in nature this can have an
impact on the prediction of pressure at the side-stream exit
and overall mixing section performance Based on basic flow
principles it was usually assumed that the static pressure
was equal between both flow streams at the mixing location
While this assumption might be used in rough calculations
the accurate simulations have shown this assumption is not
true In fact there are some points (for instance the shroud
wall at the exit of the return channel and the hub wall at
the exit of the side-stream) where this assumption is true
However this is not valid for all locations There are pressure
changes that occur from a side-stream flange to the inlet
of the next section (section-2) which depend on different
factors The first factor is the frictional losses due to side-
stream geometry from side-stream flange to plenum mix-
ing section etc The other factors are pressure changes due
to local curvature and geometry details of mixing section
Another consideration is the operation of a compressor
with side-stream at part-load The performance of the side-
wwwflowcontrolnetworkcom January 2015 25
Figure 1 An example of a centrifugalcompressor with side-stream
COURTESY SIEMENS
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 29456 January 2015
Flow Control Magazine
|
y
g
stream path the mixing section and
the downstream impellers when ma-
chine is operated at part-load or even
off-design operating flows will result
in additional compressor performance
problems In such a case both veloc-
ity profiles and pressure variations in
various parts (side-stream path mixing
section etc) will be different resulting
in complicated flow patterns and com-
plex aerodynamics behaviors
Side-Stream CompressorSectional Performance
Typically vendor-supplied compressor
performance curves reflect flange-to-flange performance because that is
what the plant engineers need to
evaluate the proper operation of their
system (for example from suction to
side-stream and from side-stream to
discharge) In many cases compres-
sor vendors also provide the over-
all compressor performance curves
and performance curves for section-1
(from suction to side-stream) and sec-
tion-2 (from side-stream to discharge)
Flange-to-flange data if not interpret-
ed properly can lead to false conclu-
sions about the relative performance
of individual sections of a compression
system For example if side-stream
losses from the flange to mixing sec-
tion are attributed to the downstream
section (section-2) it will cause the
downstream section (section-2) to
appear low in performance while the
upstream section (section-1) will show
high performance levels
An important behavior to con-
sider is when the actual side-stream
pressure is different than the rated
side-stream pressure When the side-
stream pressure is slightly higher than
the outlet pressure of the section-1
it (section-1) shows a relatively higher
performance compared to the real sec-
tion-1 performance In some cases
the performance of section-1 could be
considerably higher than section-2 In
other words when performance is de-
termined flange to flange the higher
flange pressure is seen as extra ldquopseu-
dordquo work done by the section (since this
is an inconsistent thermodynamic vol-
ume) resulting in a relatively high sec-
tional efficiency (section-1 shows a rel-
atively high efficiency) This is the case
for many compressors with side-stream
because the whole system is designed
(or specifically the side-stream location
is selected) in a way aimed at main-
taining the real side-stream pressure(side-stream inlet) above the section-1
outlet pressure because if the real side-
stream pressure becomes lower than
the section-1 outlet pressure the flow
may (theoretically) reverse
This is particularly important when
the side-stream mass flow is much
lower than the mass flow of core-flow
The above-mentioned reasons explain
why in many simulations calcula-
tions and performance reports related
to compressors with side-stream the
section-1 shows a relatively good ef-
ficiency and section-2 appears low in
efficiency
When the side-stream pressure is
slightly lower than the outlet pressure
of the section-1 the section-1 might
show a relatively lower performance
compared to section-2 This could oc-
cur in some recycle services where the
side-stream is actually a recycle flow
with a mass flow around two to five
times the core-flow The side-stream
(recycle) flow is returned from down-
stream of the compressor to be slightly
compressed and recycled to the down-
stream Such a recycled side-stream
compressor can present unique chal-
lenges for design and operation This
kind of machine usually needs very
special operating procedures and very
fine adjustments regarding operating
pressures and flows
Side-Stream Compressor
Performance amp Operation An important consideration is the sen-
sitivity of compressor overall perfor-
mance curve and sectional perfor-
mance curves to the flow ratio (ratio
of side-stream flow to core-flow) and
to the inlet conditions Variations in
the flow and pressure of the main
suction and side-stream inlet should
be controlled within tight tolerances
For compressors with side-stream the ASME PTC-10 code stipulates limits on
flow ratio (side-stream volume to core-
flow volume) The acceptable variation
in volume flow ratio in a compressor
with a side-stream is +-5 percent as
per ASME PTC code The requested
side-stream pressure tolerance is not
usually specified in compressor codes
but it should be around +- 2 percent
(or sometimes +- 25 percent)
Variance in flow ratio impacts the
velocity levels where the two streams
merge Significant variation in the ve-
locity profile upstream of the impeller
changes the incidence on the blade
leading edge of the following impel-
ler This change in incidence leads to a
change in sectional performance over-
all compressor performance and train
efficiency
If the flow ratio is varied between 95
percent and 105 percent (tolerances
specified in the ASME PTC-10 code)
the flange pressure changes accord-
ingly resulting in a change in the sec-
tional performance and overall perfor-
mance The sectional efficiency varies
sometimes more than +- 4 percent
This variance reduces as the flow is de-
creased toward surge However as the
flow is increased toward overload the
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3045wwwflowcontrolnetworkcom January 2015 27
variance increases up to higher values
(even in some cases three to five times
compared to variations near the surge
zone) For example in a case study
for a compressor with side-streams a
+- 5 percent variation in flow ratio and
associated changes (pressures losses
etc) the sectional efficiency reduced by
approximately 34 percent at the rated
flow at allowable operating points at
the end of curve (near the overload
ie choke) efficiency reduced by ap-
proximately 55 percent These results
show that the variation in sectional
performance and overall performance
due to flow ratio is highest at operat-ing points near the overload and low-
est at operating points near the surge
For compressors which work most of
the time at high flow (flow higher than
rated flow and discharge pressure low-
er than rated pressure) the effects of
flow ratio deviations (and subsequently
efficiency reduction) would be higher
than compressors working on the left-
hand side of curve (say with sufficient
margins near the surge)
In the compressor codes (such as
API 617) the compressor power varia-
tions should be maintained below 4
percent However in some applica-
tions clients require tighter tolerances
on the consumed power sometimes
below 2 percent (or even below 15
percent) Some studies suggest while
+- 5 percent of volume flow ratio is
suitable for performance test as per
ASME PTC-10 code some plants re-
quire tighter control on the consumed
power and compressor performance
(lower limits on the efficiency) the tol-
erances on the volume flow ratio could
be tighter than ASME PTC code In this
regard +- 4 percent tolerance can be
suggested on the volume flow ratio (ra-
tio of side-stream flow to core-flow) of
compressors with side-streams
Based on operational experiences
acceptable variations in volume flow
ratio and inlet pressures (suction inlet
and side-stream inlet) of a compressor
with side-streams are +- 4 percent
and +- 2 percent respectively
Another important consideration is
the required adjustments for the flow
ratio (side-stream flow to core-flow)
Compressors with side-stream usually
require fixed side-stream flange pres-
sures For a compressor with some variations in operation conditions (even
small changes) it is not usually pos-
sible to achieve optimum operation by
keeping the flow ratio (side-stream to
core-flow) constant The flow ratio has
to be adjusted according to the inlet
flow at which the machine is operating
in order to get the required correspond-
ing side-stream flange pressure
Thermal changes have also been
known to cause some instability in
centrifugal compressors An example is
the thermal-induced change of resid-
ual unbalance For compressors with
side-streams which feature tempera-
ture differences between core-flow and
side-stream flow the thermal behav-
ior of the compressor is usually more
complex and requires more attention
Heavy Gas ChallengeHeavy gases (such as heavy hydrocar-
bon gases eg propane propylene
MTBE (Methyl Tertiary Butyl Ether))
have very low gas sonic velocities that
produce high Mach numbers in the
aerodynamic flow paths For these
services because of high Mach num-
ber high flow coefficient stages have
very narrow flow maps characterized
by limited surge and choke margins
Compressors with side-streams in
these services present great challeng-
es This is to say the side-streams and
associated mixing further complicate
design operation and performance
prediction because the pressure tem-
perature and flow conditions at each
one of these side-streams as well
as at the exit of the machine require
stringent tolerances to optimize the
overall efficiency and performance
As such it is important to accuratelymodel design operate and moni-
tor performance characteristics of any
impellers diffusers return channels
and generally all flow-path components
in a compressor with side-stream FC
Amin Almasi
is a senior rotating
machine consultant
in Australia He is
a chartered profes- sional engineer of
Engineers Australia
(MIEAust CPEng ndash
Mechanical) and
IMechE (CEng MIMechE) holds
bachelorrsquos and masterrsquos degrees
in Mechanical Engineering and is
a registered professional engineer
in Queensland He specializes in
rotating machines including cen-
trifugal screw and reciprocating
compressors gas turbines steamturbines engines pumps subsea
offshore rotating machines LNG
units condition monitoring and reli-
ability Mr Almasi is an active mem-
ber of Engineers Australia IMechE
ASME and SPE He can be reached
at aminalmasiymailcom
Amin Almasi
Compressor | Gas Flow | Performance Curve | Side-Stream Flow
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3145
The pressure in the stuffing box
containing the packing can be estimat-
ed by the following equation
SBP = [Discharge ndash Suction] 3 + Suction
Pressure at the bottom of the stuff-
ing box will be higher than the suction
pressure but considerably lower than
the discharge pressure It should be
noted this calculation will yield a con-
servative estimate of stuffing box pres-
sure that can be further reduced by
pump design
A hole in the stuffing box serves as
a port for injecting clean fluid that cir-
culates around a lantern ring aligned
under the flush port The fluid flushes
solids back into the process to protect
the packing from abrasive wear If the
clean fluid is injected at a pressure ex-
ceeding that at the bottom of the stuff-
ing box some of it will leak back into
the process and some will leak out to
the atmosphere Recommended flush
injection pressure is 15ndash30 PSI (1ndash2
Bar) greater than the pressure at the
bottom of the stuffing box
Fluid injection is also used to lubri-
cate and cool dry-running packing that
is subject to frictional heat and to pre-
vent air from entering the pump which
reduces flow and operating efficiency
Centrifugal pumps utilize three
types of impellersmdashopen semi-open
and closed (Figures 2 3 amp 4) Open
designs prevent fluids with large solids
from clogging the impellers but at theexpense of pump efficiency Backing
plates on semi-open designs serve to
trap the fluid for more efficient opera-
tion Closed impellers are for use with
clean fluids since solids could ac-
cumulate in the eye which would re-
quire tearing down the pump to remove
them
Single-Stage CentrifugalPumpsSingle-stage centrifugal pumps typi-
cally have good bearing support of the
shaft with few run-out or ldquowhiprdquo prob-
lems However in some cases they
are subject to cavitation This occurs
in the eye of the impeller where the
fluid is under vacuum If the pressure
is low enough it will cause the material
to vaporize forming air or water vapor
bubbles As the fluid passes through
How Pumping Systems Design Affects Sealing Performance
By Chris Boss
8 January 2015
Flow Control Magazine
|
Understanding how different types of pump designs impact
sealing is critical to optimizing efficiency safety and lon-
gevity of the sealing system Used for a wide variety of media
including clear fluids solutions and slurries single-stage
centrifugal pumps are one of the most common
types (Figure 1) Fluid drawn into these pumps
enters the eye of an impeller that spins itto the outside of its container
or volute building pressure as
it moves toward discharge
Some of this fluid will work
its way behind the impeller
where it must be sealed with
compression packing or a
mechanical seal
Figure 1
Figure 2 Figure 3 Figure 4
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3245
the pump under increasing pressure
these bubbles implode sending shock
and vibration through the impeller
adversely affecting the seal This phe-
nomenon can be mitigated by running
the pump at slower speed and higher
pressure at the suction end to prevent
air from entering the fluid
Double-Ended Split-CasePumpsOperating on the same centrifugal prin-
ciple but slightly different geometry are
double-ended split-case pumps (Figure
5) Fluid enters both ends of the pump
and is directed into the eye of an impel-ler which spins it out of the volute to
discharge Packing is installed on both
the shaft and bearing ends so the stuff-
ing box is exposed only to suction pres-
sure which is usually quite low
Axial Flow Pumps Axial flow pumps operate like hydro
turbines in reverse whereby a propeller
(or axial impeller) pushes the fluid to
discharge (Figure 6)
Since the stuffing box is located
downstream of the propeller at the dis-
charge end of the pump the packing is
exposed to the full discharge pressure
Vertical PumpsVertical turbine pumps are typically
flange-mounted on a floor extending
downward into a water-filled sump
hole (Figure 7) Available as single- or
multi-stage pumps they feature an
impeller or series of impellers rotated
simultaneously by a single shaft The
impellers increase the pressure of the
upward flow subjecting the stuffing box
to full discharge pressure
Vertical pumps can be quite long so
inadequate bearing support can cause
the shaft to run out This can induce
undesirable lateral motion on the pack-
ing Worse the packing may be forced
to serve both as a bearing and a seal To
withstand these conditions the packing
should be resilient elastic and resistant
to deformation These properties rule
out packing such as graphite foil in favor
of fiber-based materials
Multi-Stage PumpsMulti-stage pumps are used for high-
pressure applications such as feeding
the boilers in steam-powered generating
plants Stuffing box pressure can vary
with pump design and number of stag-
es Designed for clean fluids and high
operating speeds these pumps typically
have high- and low-pressure ends with ahydraulic pressure equalization line run-
ning between the stuffing boxes
Like vertical pumps multi-stage
pumps feature a series of impellers to
build fluid discharge pressure In the
case of the six-stage pump pictured in
Figure 8 fluid enters at the drive end
where a stuffing box is exposed to suc-
tion pressure Channeled from one
impeller to the next through the pump
casting the fluid can reach extremely
high pressures at discharge
A second stuffing box located at the
bearing end is exposed to an intermedi-
ate pressure from the third impeller This
pressure is greater than the suction pres-
sure but much less than the discharge
pressure which can reach 2000 PSI
Fortunately the stuffing boxes in
these pumps are not exposed to dis-
charge pressures and typically see be-
low 500 PSI which is within the range
of some packing materials
wwwflowcontrolnetworkcom January 2015 29
Figure 5
Figure 6
Figure 7
Figure 8
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 33450 January 2015
Flow Control Magazine
| Gear PumpsPositive-displacement or gear pumps
operate on a different principle than
centrifugal pumps In external gear
pumps the fluid flows around the out-
side of the gears the intermeshing
of which forces it through the pump
to discharge (Figure 9) This design
makes these pumps particularly suit-
able for use with highly viscous fluids
such as resins emulsions syrups and
adhesives As such they are used for
transfer or metering applications
It should be noted gear pumps will
continue to displace fluid as long as
their shafts are turning which can pose
a problem if a clog occurs at the dis-
charge The resulting buildup of pres-
sure can blow out seals and damage
the pump Therefore most gear pumps
have pressure relief valves to divert
fluid back to the suction side for re-
circulation through the pump Internal
gear pumps operate slightly differently
but also have pressure relief valves to
prevent damage from excessive pres-
sure (Figure 10) In both external and
internal gear pumps the maximum
stuffing box pressure is determined by
these valves
Other rotating equipment includes
mixersagitators which are similar to
pumps in terms of the speeds to which
the packing is exposed There are ba-
sically three types of mixersagitators
top- bottom- and side-entry Top-entry
models are subject to the same con-
cerns about shaft run-out ldquowhiprdquo and
lateral forces on the paddles that are
encountered in some vertical pumps
Although some fluid may splash onto
the packing these mixers basically run
dry so the packing must have the abil-
ity to dissipate the resulting frictional
heat
In bottom-entry mixers the packing
is always exposed to fluid and may also
be exposed to solids requiring abra-
sion-resistance If the seal fails the en-
tire contents of the tank will eventually
drain out onto the bearings the floor
and other components under the stuff-
ing box
The packing in side-entry mixers may
be fully or intermittently exposed to flu-
id as well as side loading and vibration
Aside from media temperature
speed and other application variables
the configurations and operating prin-
ciples of rotary-type pumps exert differ-
ent forces on the seals used to keep
them from leaking These forces can
spell the difference between accept-
able seal performance and failure
Understanding these differences has
important implications that should be
taken into account to assure proper
sealing selection for long-term trou-
ble-free performance FC
wwwgarlockcom
Chris Boss is
a senior applica-
tions engineer for
Garlock Sealing
Technologies in
Palmyra NY He
has held various
positions in produc-
tion engineering
product development and applica-
tions engineering for the companyrsquos
compression packing division He
is a BSME graduate of the State
University of New York at Buffalo Mr
Boss can be reached at 800 448-
6688 or chrisbossgarlockcom
Chris Boss
Cavitation | Centrifugal Pump | Pump Packing | Sealing System
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Figure 9
Figure 10
Aside from media temperature speed and
other application variables the configurations
and operating principles of rotary-type
pumps exert different forces on the seals used
to keep them from leaking These forces can
spell the difference between acceptable seal
performance and failure
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3445
NS IDERNDUSTRIAL AUTOMATION + PROCESS CONTROL
WANT
INFORMATION
ON THE
automationindustry
SUBSCRIBE NOW at wwwiainsidercouk
Published by Spitzer and Boyes LLC Write in 15 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3545
Frost says the push from developing
economies is important as the market
is technologically mature and seeing
restricted growth in developed econo-
mies This is particularly true in Europe
and North America where recent finan-
cial insta-
bility has
reduced capital expenditure across end-
user industries
Bill Moore senior vice president of
sales development and channel man-
agement for global bearings manufac-
turer SKF says ldquosmartrdquo products and
the expansion of robust reliability pro-
grams are helping to drive new invest-
ment particularly in developed coun-
tries where the cost to compete is
high Frost says the magnitude of
the existing global installed base will
strengthen the need for replacement
and upgrades adding to market de-
mand as well
Frost says despite the potential
in developing economies the focus
on price as a product differentiator
may lead to intense price pressures
among manufacturers and bring down
the value of the overall market in the
short term The growing trend among
consumers to choose low-cost Chinese
imports will complicate this challenge
As price and quality become stan-
dardized across the globe customers
will base more of their purchasing deci-
sions on value-added services accord-
ing to Frost This will push manufactur-
ers to create more maintenance-free
solutions such as lubrication-free
bearings that offer end-users savings
on service and replacement costs and
reduce downtimeldquoOffering a complete line of prod-
ucts with comprehensive services will
be another feather in the cap of ven-
dors looking to widen their consumer
baserdquo notes Frost Industrial Automa-
tion and Process Control Research
Analyst Guru Mahesh
Moore says the trend of outsourcing
manufacturing to regions where labor
and production costs are favorable is
becoming less of a factor
ldquoThe days when cheap labor made
a significant difference in where a prod-
uct is manufactured mdash particularly high
value-added products or high weight
and bulk products mdash are coming to
an end as the cost of transportation
storage and inventory balance out the
benefits of production costs where la-
bor is a smaller percentage of the cost
of manufacturingrdquo Moore says ldquoLocal
manufacturing development will indeed
come to developing countries as their
ability to create markets that generate
economies of scale that support local
production is a clear trend and one that
all manufacturers will pay attention tordquo
Moore says that development of
maintenance-free or predictive tech-
nologies and products will be a sig-
nificant advantage to everyone in the
Bearing amp Coupling Manufacturers Focus
onDEVELOPING Economies
amp EFFICIENCY InnovationBy Amy W Richardson
2 January 2015
Flow Control Magazine
|
gy
Anew study from Frost amp Sullivan (wwwfrostcom) fore-
casts steady growth for the overall bearings and couplings
market based on rapid industrial development in high-growth
regions Specifically Frost predicts development in Mexico
Indonesia Nigeria Turkey Brazil Russia India and Chinawill help boost the bearings amp couplings market from $2206
billion in 2013 to an estimated $2676 billion in 2018
The development of maintenance-freeor predictive technologies will helpboost growth in the bearings market For example SKF is developing products that will automatically notifyusers when a bearing or mechanicalrotating component is approachingthe end of its useful life Pictured hereis an SKF Microlog analyzer a por- table condition monitoring tool
COURTESY SKF
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
improved productivity through simplified solutions The powerful technology and tools ensure repeatable
reliable accurate measurements Easier access to process data allows for better troubleshooting process
optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
For daily product notes visit the lsquoFeatured Productsrsquo section flowcontrolnetworkcom
ON THE WEB
1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3845
FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
and benefits as well as grids of
instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
services provided for the
mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
Brought to you by Beamex
Your Source For Fluid Handling Videos
Go towwwflowcontrolnetworkcomfreeinfo
Select appropriate issue ofFlow Control Magazine
Select advertisements thatinterest you
Enter your email amp clickldquoSubmit Requestrdquo
1
2
3
4
PRODUCT
INFORMATION
ONLINE
Follow these 4 steps to receive freeproduct information from suppliers
FREE
FEATURED VIDEO How to Calibrate aPressure Measurement Loop
For more information about FlowTube
sponsor packs email FlowControlGrandViewMediacom
7232019 Flow Control January 2015
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THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
Name ________________________________________________________________
Title _________________________________________________________________
Company _____________________________________________________________
AddressCityStateZip __________________________________________________
______________________________________________________________________
Phone ________________________________________________________________
E-Mail ________________________________________________________________
One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545
![Page 6: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/6.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 645
Do you know whatrsquos
gone out the window
at your facility
Magnetrolreg energy management solutions monitor and measure the energyflowing through your facility to reduce utility costs and make processes moreefficient Easy to install and operate TA2 thermal flow meters provide you withan efficient environmentally responsible way to manage compressed air andnatural gas cost centers
Make MAGNETROL Thermatel reg TA2 mass flowmeters part of your energy management strategyVisit magnetrolcomthermalmassflow or contact
your MAGNETROL representative for more information
Measure and control your compressed
air and natural gas energy costs with
Thermatelreg TA2
991266 PDJQHWUROFRP Write in 3 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 745
1 9 9 5 - 2 0 1
51 9 9 5 - 2 0 1
5
20th20th january 2015 | Vol XXI No 1
4 | January 2015
Flow Control Magazine
departmentscolumns6 EDITORrsquoS FILE
4 flow things you need to know aboutthis month
14 APPLICATIONS CORNERa coriolis mass flowmeter providesa better solution
39 WORD SEARCH temperature measurement
40 QUIZ CORNER how to calculate orifice plate flow rate
Cover imagesFlowmetercourtesyEndress+HauserBackgroundiStock
8 NEWS amp NOTES api 624 valveemissions update intelligent features toboost desal pumps market hydraulic fractur-ing water treatment on the rise
34 UP CLOSE with Micro Motionrsquos Model5700 Coriolis Transmitter
35 NEW PRODUCTS
36 WEB RESOURCE FILE
38 ADPRODUCT INDEX
S I N C E 1 9 5 8
Itrsquos More than a Check Valve
Itrsquos a Check-All
When You Need Absolute Precision
CHECK-ALL IS THE ONLY CHOICE
Our spring loaded check valves are assembled
to your exact needs ensuring absolute precision
and reliability They work like they should Plus
most lead times are less than one week Thatrsquos
what makes Check-All the only choice
Get me a Check-AllManufactured in
West Des Moines Iowa USA515-224-2301 bull salescheckallcom bull wwwcheckallcom
Write in 4 or Request Info Ins tantly at wwwFlowControlNetworkcomfreeinfo Write in 5 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
Return on investment calculations for plant upgrade or new
plant construction projects may go through several iterationsbefore the trigger is finally pulled or indeed not pulledldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 845
The new Ultratrade 8c The capability and performance
your market demands
Copyright copy FMC Technologies Inc All Rights Reserved
FMC Technologiesrsquo Ultra 8c ultrasonic owmeter shares the advanced technology
of the next generation Smith Meterreg Ultra Series meters With its touchscreen
interface upgradable memory and high-speed processor the Ultra 8c provides
cutting-edge performance and diagnostic ability And with additional measurement
paths the Ultra 8c has even better cross-ow and swirl compensation for improved
accuracy and repeatability Whether for leak detection or custody transfer theUltra 8c gives you the assurance of superior performance in the eld even for the
most viscous crude oils in todayrsquos market
For more information visit wwwfmctechnologiescomultrafc
wwwfmctechnologiescom
Write in 6 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 945
20 Years of Flow Control This
year marks the 20th Anniversary of
Flow Control magazine Launched
in 1995 with the aim of serving technical
professionals involved with designing oper-
ating and maintaining fluid handling systems in a wide range of
industries Flow Control has leveraged its many years of experi-
ence to establish a unique niche and reputation for providinghigh-quality information to you our subscribers I congratulate everybody who helped
Flow Control get to where it stands today Herersquos to another 20 years of success
Training Time Itrsquos a new year and we have two new
training opportunities for
you to enhance your skillset in 2015
Regular Flow Control columnists Da-
vid W Spitzer and Larry Bachus will
be presenting three-day courses on
Flow Measurement and Pumping
Systems respectively I encourage you and your colleagues to take ad-
vantage of these important training
opportunities For more details see
flwctrlcomflowseminar amp
flwctrlcompumpguy
Oil amp Gas Gender Gap Results of a
new global workforce survey conduct-
ed by OilCareerscom and Air Energi
show a gender gap in the oil amp gas industry
persists despite ongoing efforts to recruit more
women into the industry According to hiring
managers the
top three factors
that significantlycontributed to
the gender gap
in the oil amp gas
industry are
1 A lack of women entering the industry (55
percent)
2 An industry culture created by a male-domi-nated environment (53 percent)
3 The logistics requirement ie travel shift
and working patterns in the field (30 percent)
For more on this story and an infographic seeflwctrlcomog_gendergap
Rockwell Automation Fair 2014 Our colleagueKevin Parker at Processing magazine attended the
annual Rockwell Automation Fair Nov 9-10 in
Anaheim Calif Parker gleaned some interesting perspec-
tive on key trends in process automation including
1 Hardware and software are more blended than ever
2 Fog computing (a kind of cloud computing) is making
headway in industrial engineering environments where latency is a critical concern
For Parkerrsquos full report from the Automation Fair see flwctrlcomrockwellfair2014
DITORrsquoS FILE
6 | January 2015
Flow Control Magazine
4 Flow Things You Need to Know
GROUP PUBLISHERPROCESSINGFLOW CONTROL
MICHAEL C CHRISTIAN | (908) 507-5472mikecgrandviewmediacom
NATIONAL ACCOUNTS MANAGERJIM SEMPLE | (908) 963-3008 jsemplegrandviewmediacom
EXECUTIVE DIRECTOR OF CONTENTMATT MIGLIORE | (610) 828-1711
mattgrandviewmediacom
MANAGING EDITOR AMY W RICHARDSON | (205) 408-5050
arichardsongrandviewmediacom
COLUMNISTS
LARRY BACHUSDAVID W SPITZER JESSE YODER
ART DIRECTORJULIE FLYNN
juliegrandviewmediacom
MANAGER - DIGITAL OPERATIONSMARY BETH ROMANO
SUBSCRIPTION amp REPRINT REQUESTSflowcontrolhalldatacom
Administrative TeamGENERAL MANAGER
BARRY LOVETTE
CHIEF OPERATIONS OFFICERBRENT KIZZIRE
VICE PRESIDENT OF FINANCEBRAD YOUNGBLOOD
VICE PRESSIDENT OF B2B GROUPMIKE WASSON
CHIEF REVENUE OFFICERCHRIS DOLAN
VP AUDIENCE DEVELOPMENTDELICIA POOLE
AUDIENCE DEVELOPMENT MANAGER ANNA HICKS
DIGITAL AUDIENCEDEVELOPMENT ANALYST
STACY BARNES
EDITORIAL ADVISORY BOARDLarry Bachus Bachus Company IncGary Cornell Blacoh Fluid Control
Jeff Jennings Equilibar LLCMitch Johnson JMS SoutheastPeter Kucmas Elster Instromet
Jim Lauria Water Technology Executive
John Merrill PE EagleBurgmann IndustriesSteve Milford Endress+Hauser US Tom OrsquoBanion Emerson Process
Management Micro MotionDavid W Spitzer PE Spitzer and Boyes LLC
Tom Tschanz McIlvaine Company John C Tverberg Metals and Materials
Consulting EngineersJesse Yoder PhD Flow Research Inc
WINNER
WINNER WINNER
PERSPECTIVES FROM THE MONTH THAT WAS IN THE WORLD OF FLOW CONTROL
WINNER WINNER
THE
NETWORK
1
2 3
4
1 9 9 5 - 2 0
1 51 9 9 5
- 2 0 1 5
20th20th
Matt Migliore Executive Director of Content MattGrandViewMediacom
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1045
Endress+Hauser Inc
2350 Endress Place
Greenwood IN 46143
infousendresscom
ww wusendresscom
Sales 888-ENDRESS
Service 800-642-8737
Fax 317-535-8498
Guided wave radar level products - built for safety precision and efficiency
bull Reliable non-contact measurement even for changing process conditions
bull HistoROMreg data management - concept for fast and easy
commissioning maintenance and diagnostics
bull Multi-Echo Tracking evaluation - highest reliability even with the
presence of obstructions in the vessel
bull Hardware and software developed according to IEC61508 up to SIL3(in homogeneous redundancy)
bull Seamless integration into control or asset management systems
bull Worldrsquos easiest proof test concept for SIL saves time and cost
wwwusendresscommicropilot-radar-level
The newest generation of Micropilot
Taking your process to the next level
Write in 7 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1145
HE OUTLOOK | News amp Notes
1 ISO15848 ldquoMeasurement test and qualification proce-
dures for fugitive emissionsrdquo
a Part I ndash ldquoClassification system and qualification proce-dures for type testing of valvesrdquo
b Part II ndash ldquoProduction acceptance test of valvesrdquo
2 API 622 ldquoType Testing of Process Valve Packing for Fugitive
Emissionsrdquo
3 End-user defined fugitive emission reduction requirements
Key aspects of valve testing per API 624 include
The standard covers rising and rising-rotating stem
valves up to 24rdquo diameter
Class 1500 valves are not covered
The test medium is methane
310 test cycles are required with three thermal cycles Temperature application range is from -29 C to 538 C
with last cycle 10 cycles user-defined (can be -45 C)
Re-tightening of gland bolts is not permitted during test
Valve stem test orientation is vertical
Several valves must be tested to achieve API 624 com-
pliance Similar industry principles applied to test valves
qualify two nominal sizes smaller one size larger and one
pressure class below
Allowable leakage is 100 PPM maximum
Gate and globe valves need to be tested separately
For example Gate Valves per API602 four tests API600
eight tests (up to 20rdquo diameter) API 603 eight tests andfor Globe Valves per API 602 four tests
Test valves should be production valves not specially
manufactured test valves
As a result of the release of API 624 testing companies have
been gearing up for an increase in the number and size of
test valves and new test houses are coming to market Withthis in mind implementation of API 624 needs to be carefully
monitored and claims from valve manufacturers should be
validated by requesting to view test results Important factors
to be mindful of include
Number of cycles on some valves could be detrimental
to packing as certain smaller size valves donrsquot come with
grease ports to keep the stem lubricated all of the time
Test failures of valve stem threads yokes and glands
Grease traps into packing and causes leakage
At higher temperatures a few greases create volatile
organic compound and burn off
Testing in vertical generates more heat in yoke area
Certain challenges need a good testing company that has
experience in testing on fugitive emissions and provides
guidelines to manufacturers in terms of use of packing valve
grease testing requirements etc
A preliminary survey was conducted with end-users regard-
ing current utilization and application of API 624 For a sum-
mary of responses from this survey visit flwctrlcom1oWijWz
Gobind Khiani PEng is with Fluor Canada Ltd Khiani has
spent 20-plus years in the energy and power business and 10-
plus years in the Western Canadian oil and gas industry Hecan be reached at 403 850-6982 or gobindkhianifluorcom
Valve Standards UpdateEnd-users ramp up compliance efforts for API 624
as new specifications emerge on the horizon
8 | January 2015
Flow Control Magazine
By Gobind Khiani
In the May 2014 issue of Flow Control (page
16) the new standard API 624 ldquoType Testing
of Rising Stem Valves Equipped with Graphite
Packing for Fugitive Emissions First Editionrdquo was
addressed This standard which was published
and put into effect in February 2014 estab-
lishes guidelines for testing industrial valves for
emissions compliance Since the publication ofthe May article further requests from industry
have spurred the creation of another specifi-
cation API 641 ldquoType Testing of Quarter-Turn
Valvesrdquo and an API ldquoPiping and Valvesrdquo commit-
tee has been formed Regulators and end-users
are also working on
1992 1998 2003 2008 2013 2020
4
35
3
25
2
15
1
05
0
M i l l i o n o f
t o n n e s y e a r Will API 624
have a stepeffect in reducing
fugitiveemissions
Global valve fugitive emissions
End User response at best
End User response actual
S O U R C E G O B I N D K
H I A N I
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1245
Intelligent Features to Boost Global WaterDesalination Pumps Market
The Global Water Desalination
Pumps Market is expected to grow
at a CAGR of 77 percent from 2015 to
2019 according to a new report from
TechNavio (wwwtechnaviocom)
The report shows demand for water
treatment has increased significantly in
developing countries where fresh wa-
ter resources can be scarce Providing
clean and potable water to huge popu-
lations has become a priority which is
pushing the demand for water desalina-tion pumps in the market according to
TechNavio
The report emphasizes the emer-
gence of intelligent pump systems as
a major driver of market growth In-
telligent pumps possess the ability to
regulate flow and pressure and these
systems can automatically adjust to
process and pump system changes
ldquoIntelligent pump systems are be-
ing adopted by many manufacturers
because of the high level of fault toler-
ance ability which leads to a significant
reduction in the total cost of owner-
shiprdquo said Faisal Ghaus vice president
of TechNavio in a news release ldquoThe
adoption of these systems will also
help industries comply with current Eu-
ropean Union regulations in relation toreduction in energy consumptionrdquo
The growing demand for clean wa-
ter worldwide will continue to augment
the demand for water desalination sys-
tems which will propel the Global Water
Desalination Pumps Market during the
forecast period
trendlines
wwwflowcontrolnetworkcom January 2015 | 9
Write in 8 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
Intelligent pump sys-tems are being adopt-
ed by many manufac-
turers because of the
high level of fault tol-
erance ability which
leads to a significant
reduction in the total
cost of ownership
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1345
HE OUTLOOK | News amp Notes
10 | January 2015
Flow Control Magazine
Hydraulic Fracturing WaterTreatment amp Reuse Expected to Soar
Wastewater treatment spending for
hydraulic fracturing is expected to
grow almost three-fold from $138 mil-
lion in 2014 to $357 million in 2020 in
the US according to a new report from
Bluefield Research
The US hydraulic fracturing industry
consumes over 1 billion barrels of wa-
ter annually producing 450ndash500 mil-
lion barrels of contaminated water for
disposal with only about 14 percent
treated and reused Bluefield cites watersupplies increasingly at risk tighter regu-
lations emerging in key states and costs
of disposal on the rise as factors con-
tributing to the substantial rise in water
treatment and reuse which is expected
to account for 27 percent of total pro-
duced and flowback water by 2020
Overall the US hydraulic fracturing
industry will spend $638 billion in 2014
on water management Water transport
and disposal costs will account for 66
percent of the total water managementspent this year with treatment compris-
ing roughly 2 percent
Bluefield reports water scarcity in
Western US states has had little im-
pact to date on fracturing water supply
but that is likely to change if droughts
persist Meanwhile state regulators are
beginning to tighten control of produced
water disposal In Pennsylvania where
policymakers in 2010 placed discharge
limits on wastewater from unconven-
tional oil amp gas operations statewide
treatment and reuse rates for the Mar-
cellus jumped to 90 percent in 2014
The increasing cost of transport and
injecting water into wells mdash now ac-
counting for 66 percent of water servicesspending mdash and the improving cost
structures of treatment provide another
driver of reuse Bluefield reports Well
operators that employ treatment and re-
use solutions spend on average $880
per barrel of water used compared to
$1020 per barrel of water trucked and
injected into wells although cost com-
parisons are site specific
ldquoFracking has been the Wild West for
the US water industryrdquo said Reese Tis-
dale president of Bluefield Research ina prepared statement ldquoThere are three
reasons for this first there has been
an explosive build-out of fracking well
installations now surpassing 126000
Second there has been a lack of clear
regulation on water management in key
markets And third there is not a one-
size-fits-all treatment solution for frack-
ing meaning solutions providers have
had to ascend a steep learning curve
to treat the variable wastewaters that a
single well is capable of producingrdquo
Tisdale notes that these inhibitors
while still acute are beginning to take on
a new form This is partially due to signifi-
cant gains in water management experi-
ence realized adoption of more efficientwater management strategies among
well operators and the emergence of
new policy mechanisms from regulators
that are playing catch-up with the fast-
moving hydraulic fracturing industry
trendlines
Treatment2
Disposal
6
Supply10
Storage22
Transport60
US $638Billion
S O U R C E B L U E F I E L D R
E S E A R C H
Write in 23 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
Industry-Leading
Warranties
Temperature Measurement Solutions
bull Probe type industrial RTDsbull Electronic temperature switchtransmitter bull Vapor-actuated remote thermometersbull Digital temperature indicatorsbull Platinum resistance temperature transmitterbull Compact OEM temperature transmitter bull Industrial amp instrument type bimetal thermometersbull Thermowells
1010 West Bagley Road I Berea Ohio 44017 I P 4402430888 I F 4402433472wwwnoshokcom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1445
New Technique Could ReduceEnergy Required for Oil Refinement
UK scientists have developed a
technique they say has the poten-
tial to dramatically reduce the amount
of energy required for the refinement
of crude oil
Professor Martin Schroumlder and Dr
Sihai Yang from The University of Not-
tingham (wwwnottinghamacuk ) have
led a multi-disciplinary team of scien-
tists from Nottingham the Science and
Technology Facilities Councilrsquos (STFC)
ISIS Neutron Facility Oak Ridge Na-tional Laboratory and Diamond Light
Source to discover a porous material
that works like a chemical sponge to
separate a number of important gases
from mixtures generated during crude
oil refinement
According to a news release from
The University of Nottingham the ex-
isting industrial process uses ldquohuge
amounts of energy to separate and pu-
rify these gases so the new technique
has the potential to revolutionize the oil
industry by significantly reducing car-
bon emissions and making the process
more environmentally friendlyrdquo
Commercially UsefulCrude oil is a raw material that is
refined to produce fuel for cars toheat homes and to create polymers
and other useful materials It is made
up of a complex mixture of hydro-
carbons (chemical compounds that
contain only hydrogen and carbon) of
which certain components are espe-
cially commercially useful
One industrial process used to
achieve hydrocarbon separation is
called ldquocryogenic distillationrdquo which is
widely used worldwide and uses vast
amounts of energy to generate the high
pressures and cryogenic temperatures
required to ensure efficient separation
research amp development
wwwflowcontrolnetworkcom January 2015 | 11
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I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1545
of hydrocarbon mixtures into pure components
However researchers say an innovative solution may
have come in the form of a novel chemical sponge This
porous material a metal-organic framework was devel-
oped by the same team at Nottingham just two years ago
Now in research published in Nature Chemistry for the
first time scientists have proven that it can be used toseparate hydrocarbon mixtures without the need for high
process pressures or very low process temperatures
Reusable MaterialsMade from cheap organic materials aluminum nitrate
salt and water the porous material called NOTT-300 is
able to adsorb different gases found in mixtures of hydro-
carbons at different rates making it possible to sepa-
rate them and extract the most useful ones NOTT-300
requires less energy to function than existing methods
as it operates at ambient temperatures and normal pres-
sures researchers say The gases that are adsorbed intoNOTT-300 can be removed without a significant energy
input and therefore the material can be easily reused
The team of scientists from Nottingham used Diamond
the UKrsquos synchrotron science facility as well as STFCrsquos
ISIS Neutron Facility and Oak Ridge National Laboratory
the UKrsquos and USArsquos world-leading neutron facilities re-
spectively to prove that the sponge works under real-life
conditions
Professor Martin Schroumlder Dean of the Faculty of Sci-
ence at Nottingham said in the news release ldquoIt is a very
important to be able to separate different hydrocarbons ef-
fectively and efficiently with low-energy consumption Po-rous solids such as the metal-organic framework system
studied here represent important materials for the future
development of low-energy separation technologies We
are most grateful to our collaborators at ISIS Neutron Fa-
cility Oak Ridge National Laboratory and Diamond Light
Source in bringing this work to fruitionrdquo
Significant Impact on Oil IndustryDr Sihai Yang the winner of Diamond Young Scientist
and BTM Willis Prize is a Senior Research Fellow at
Nottingham He led the project together with Professor
Martin Schroumlder Yang said ldquoWith the help of advancedcentral facilities like Diamond ISIS and ORNL we have
developed a new separation technique which can poten-
tially reduce the energy usage associated with oil petro-
leum and chemical industries which require the separa-
tion of raw hydrocarbons from crude oil
The discovery of the new material NOTT-300 could
have a significant impact on the oil industry by removing
the necessity for some energy-intensive refinement pro-
cesses researchers say
The research was funded by Engineering and Physical
Sciences Research Council (EPSRC) the European Re-
search Council (ERC) The University of Nottingham andLeverhulme Trust
12 | January 2015
Flow Control Magazine
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Monitor your Total Acid Consumption
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THE OUTLOOK | News amp Notes
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httpslidepdfcomreaderfullflow-control-january-2015 1645
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 174514 | January 2015 Flow Control Magazine
PPLICATIONS CORNER | Process Instrumentation
This is the final article in a series based on the troubleshoot-
ing of a mysterious unit shutdown due to flowmeter perfor-
mance problems
If yoursquove followed this column for most of 2014 you know
that what should have been a liquid ammonia stream to the
feed plant became problematic due to the occurrence of
bubbles of ammonia gas These bubbles caused an ultrasonic
flowmeter in a unit to indicate zero flow and caused the reactor
to scram (shut down) under warm operating conditions The source of the bubbles was traced back to the pres-
sure drop associated with a control valve located at the
exit of the liquid ammonia tank farm
This issue was resolved by identifying the problem
and fixing it at its source This was a pragmatic ap-
proach at the time (early 1980s) given the operation
of the cooling system in the unit and the limited selec-
tion of applicable flowmeter technologies
By the early 1990s changes were implemented that elim-
inated all process cooling requirementsmdashexcept for the small
jacketed cooler upstream of the liquid ammonia flowmeter In
other words after these changes the entire cooling system
would be operated and maintained to cool a few meters of
one small ammonia pipe Coincidently at about the same
time Coriolis mass flowmeters became more mature and
could reasonably measure the mass flow of liquid streams
with homogeneous low levels of vapor
The convergence of these two events resulted in another
approach to the problem that was not available in the early
1980smdashie install a Coriolis flowmeter that could operate in
the presence of bubbles The purchase and installation of a
Coriolis mass flowmeter was given high priority given its im-pact on unit operation economics and safety (by eliminating
the ldquomidget-makerrdquo (see March 2014 page 14))
Plant requirements and the technology that can meet
plant needs keep changing An excellent solution today can
become outdated in just a few years However there are few
substitutes for understanding fundamentals when addressing
a problem In other words there can be more than one way
to skin a cat FC
wwwspitzerandboyescom
Problem Solved AgainA Coriolis mass flowmeter provides a better solution
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1384 POMPTON AVENUE CEDAR GROVE NEW JERSEY 07009
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bull Wide range of pressuresettings
bull PTFE shaft and diaphragm designs
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David W Spitzer
Ammonia Gas | Coriolis Flowmeter | David W Spitzer | Scram | Troubleshooting
FLOWSTREAM Find related content flowcontrolnetworkcom
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and Boyes
LLC offering engineering seminars strategic marketingconsulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer can be reached at 845 623-
1830 or at wwwspitzerandboyescom
The purchase and installation of a
Coriolis mass flowmeter was given
high priority given its impact on unit
operation economics and safetyldquordquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1845
Smart Valve Positioner
Beyond Control The NEW Research Controlreg SRD positioner does
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plus more The SRDrsquos comprehensive diagnostics tool
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compatible with Research Control valves and most other
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1945
Process improvements to increase yield or cut manufactur-
ing costs typically require enhanced process control but the
installed base of measurement instrumentation in a process
plant may simply be unable to facilitate improvements because
of age inadequate performance or unreliability Maintenance
cost and unscheduled process downtime for an aging process
plant can be very damaging to the balance sheet Upgrading
to new more accurate and more reliable instrumentation can
be prohibitively expensive New plant construction must alsomaintain a focus on optimizing costs for the process control
infrastructure The budget approval decision for new plant
construction must weigh such costs against projected market
conditions for the products that the plant is intended to manu-facture In todayrsquos volatile global marketplace return on invest-
ment calculations for plant upgrade or new plant construction
projects may go through several iterations before the trigger is
finally pulled or indeed not pulled
This article describes advances in two-wire instrumenta-
tion specifically in relation to flowmeters that have taken
place in the past few years and the significant cost benefits
that this new technology can realize for plant builders and op-
erators in terms of capital investment and cost of ownership
The Significance of Two-Wire Loop Power
A survey involving 204 participants in the chemical indus-try across Germany Switzerland the UK Canada and the
United States (Manfred Koenig PhD KIM Ludwigshafen
Germany 2006) revealed an 87 percent preference for two-
wire instrumentation versus four-wire in process applications
and 89 percent for utilities This overwhelming preference
may stem from the fact that older process plants were built
with two-wire twisted-pair cable networks connecting all
process units and measuring instruments together in an
overall plant control scheme
However these existing cables are relatively unsophisti-
cated and incapable of supporting anything but low-energy
instrumentation that is insensitive to interference from otherelectrical sources that might be sharing the same cable con-
duit Further the low energy levels supported by these two-
wire loops are more easily rendered safe in terms of explo-
sive risk in hazardous areas containing flammable materials
Many older process plants are also likely to have a significant
installed base of flowmeters employing pre-war (pre-1945)
technology such as positive displacement (PD) turbine vari-
able area (VA or Rotameter) and differential pressure (dP)
Market data firm Flow Research Inc (wwwflowresearch
com) indicates collectively a future compound negative annual
growth rate approaching minus 3 percent to 5 percent for PD
turbine and VA flowmeter types while dP is expected to keeppace with market growth (World Market for Flowmeters 2010)
YSTEMS DESIGN | Flow Measurement
16 | January 2015
Flow Control Magazine
The Two-Wire
ADVANTAGENew wiring options enable modern instrumentsto drive cost savings in existing plant systems
By Steve Milford
Advances in two-wire instrumentation have enabled mod- ern technology to be employed to the advantage of older
plant and process systems
Some chemical manufacturing plants are
competing for survival not only externally
against other global companies but also
internally among the global facilities of theirown company Other industry sectors face
similar challenges
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2045wwwflowcontrolnetworkcom January 2015 | 17
The Need to Replace Older TechnologiesUntil the 21st century two-wire loops were only able
to support these relatively unsophisticated instruments
which convert their measurement by various means into a
4-20mA output or pulse signal to the control system The
more advanced post-war flowmeter technologies such as
Coriolis ultrasonic or electromagnetic flowmeters have
until just eight years ago required a dedicated power sup-
ply for their function in addition to the output loop and
thus a four-wire infrastructure was required as a minimum
Therefore upgrading older two-wire meter devices to moremodern four-wire technology could require significant
expenditure in terms of the installation of separate power
cables and supply modules
There was a major breakthrough in 2006 when a true
two-wire loop-powered inline liquid ultrasonic flowmeter
was introduced (Figure 1) The nature of this breakthrough
was innovation in device power management This was the
missing piece up to that point because to be a true loop-
powered device the meter had to directly provide a full 16
mA span using less than 36 mA of remaining loop current
and less than 1 Watt of electrical energy The flowmeter
operated on a single 4-20 mA HART two-wire loop wasremotely powered by a DC supply was certified Class 1 Divi-
sion 1 and could be deployed as Intrinsically Safe through
the use of an approved safety barrier
A true two-wire loop-powered Coriolis flowmeter followed
in 2011 (Figure 2) employing a new and more advanced
common electronics platform A two-wire loop-powered inline
ultrasonic flowmeter for low-pressure gas was introduced in
2012 and a second two-wire loop-powered Coriolis meter fol-
lowed in 2013 offering improved measurement performance
and an additional high-performance meter tube material
Electromagnetic and vortex flowmeters had already been
available for some years in two-wire loop-powered form butimproved performance resulted as these designs were incor-
COURTESYENDRESS+HAUSER
Figure 1 A two-wire ultrasonic flow- meter released in 2006 operated ona single 4-20 mA two-wire loop
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I I I I LL I
I I I I LL I
copy COPYRIGHT 2015 OMEGA ENGINEERING INC ALL RIGHTS RESERVED
1-888-826-6342
Prices listed are those in effect at the time of publication and are subject to change without noticePlease contact OMEGArsquos sales department for current prices
FPD3000 SeriesStarts at$630
FPD3300 SeriesStarts at
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OSXL-TIM3$999
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Positive Displacement Flow Meterfor Fuels and Oils
bull Aluminum Bodybull FKM Sealsbull Temperatures up to
80ordmC (176ordmF)bull NPT or BSP Threadsbull DIN JIS or ANSI
Connection (Availableon 1 and Larger Sizes)
Positive DisplacementFlow Meter for Solvents
Thermal Imaging CameraFor Inspection andFactory Diagnosis
Note Not for ExportUSA Only
Your One-StopSource for Process
Measurement and Control
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 214518 | January 2015
Flow Control Magazine
porated into their new common electron-
ics platform in 2013 So all the ldquomodernrdquo
flow measurement technologies mdash that
is to say those introduced post-war mdash
have become available as two-wire loop-
powered devices with one exception
namely thermal mass (thermal disper-
sion) meters Unfortunately the power
requirements for this technology exceed
what is currently deemed possible withtwo-wire loop-power management
Payback forTechnology UpgradeConsider a 1rdquo process line
containing a liquid process
ingredient costing $1lb at a
mass flowrate of 150 lbmin-
ute We have $150minute
flowing in the line translating
to $9000hour and $72000
per eight-hour shift That cal-culates further to $360000
per five-day working week and
for a working year of 40 weeks for
example that is $144 million Assume
the existing device is a turbine flowmeter
Now imagine a two-wire loop-
powered Coriolis mass flowmeter is
installed in place of the existing meter
The line would need to be drained and
probably one process flange replaced
allowing the Coriolis to fit mechanically
in place of the turbine However thetwo-wire loop already used for carrying
the existing meterrsquos flow signal to the
control room can be used unaltered
for the complete electrical installation
aspects of the Coriolis flowmeter
The upside of the change is signifi-
cant and clear cut Assuming the exist-
ing meter measurement uncertainty was02 percent of reading then measure-
ment uncertainty improves through use
of Coriolis to 01 percent of reading
giving a 01100 x $14400000 im-
provement in control of the ingredient
annually or $14400 A two-wire Coriolis
mass flowmeter with 01 percent mass
flow accuracy would be paid for in ap-
proximately 6-8 months In practice the
improvement in measurement uncer-
tainty would be greater as the operator
would gain temperature and density in-formation from the Coriolis and the mea-
surement would be devoid of any fluid
property dependence Viscosity change
for example can have a major impact on
turbine meter performance Mechanical
wear and tear that turbine meters even-
tually experience which causes them to
under-register flow is precluded by mod-
ern devices like Coriolis
Furthermore if the process ingredient
was being blended with another then ad-
ditional process improvements could berealized through in-line blending control
using Coriolis technology for final density
as the control point It is possible to have
dual 4-20 mA outputs from two-wire
loop-powered meters but as the main
4-20 mA output representing the prima-
ry variable is also HART then an external
HART Loop Converter or HART IO card in
the control system can provide second-
ary tertiary and quaternary variables as
4-20 mA signals A Coriolis meter is trulya multi-variable device Certain two-wire
devices are also available with Profibus
or Foundation Fieldbus communication
Cutting Wiring CostsIn 2003 WIBEXERA (International
Instrument Usersrsquo Associations) Report
T 2732 X 03 was published and it pro- vided an average survey of prices quoted
in projects at that time for the provision
of power supplies for four-wire instru-
ments The price ranged from euro1200
to euro1800 per instrument depending
upon design and plant characteristics
for an average cost of euro1500 (about
$2000) It would be reasonable to
assume an inflationary factor of 2 per-
cent per annum giving an approximate
current-day figure of $2500
From another source within thechemical industry an estimation of
$40foot to $50foot was given for in-
stallation of four-wire cabling For a
linear 50-foot cable run with for ex-
ample a 10-foot vertical at each end
this equates to $3150 Actual costs
and budget estimates have been given
as high as $10000
The Extent of the Opportunity The modern post-war flow measure-
ment technologies have different powerrequirements and consequently they
are not all available for the
same size range in two-wire
loop-power form For example
two-wire Coriolis flowmeters
are limited to 2rdquo diameter
electromagnetic and inline
low-pressure gas ultrasonics
are limited to 8rdquo and vortex
and inline liquid ultrasonic are
limited to 12rdquo
Nevertheless for thechemical industry in particu-
lar perhaps two-thirds of the
process pipes in a plant will be no larger
than 2rdquo and even when the host process
pipe is larger a correctly sized flowmeter
can still be less than 2rdquo There is consid-
erable scope for two-wire loop-power to
deliver value for flow measurement ap-
plications with total safety
The virtues of Coriolis technology
have been covered but what about
other two-wire technologies An elec-tromagnetic flowmeter in two-wire form
YSTEMS DESIGN | Flow Measurement
In todayrsquos volatile global mar-
ketplace return on investment
calculations for plant upgrade or
new plant construction projects
may go through several itera-
tions before the trigger is finally
pulled or indeed not pulled
ldquo
rdquo
COURTESYENDRESS+HAUSER
Figure 2 Two-wire Coriolis flowme- ters became available in 2011
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2245
can be used on water wastewater or
a light water-based slurry provided the
fluid has around a 20 microSeimenscenti-
metre (microScm) electrical conductivity
A magnetic flowmeter is full bore un-
less flowrates dictate a reduced meter
size in the interests of performance and
so there are no intrusions into the flow
stream and no pressure loss An accu-
racy of 05 percent of reading is normal
from a two-wire magnetic meter and a
modest five diameters (5D) of straight in-let run is needed to avoid error from up-
stream flow disturbances When the fluid
exhibits insufficient conductivity then
the same performance and installation
requirements can be met by an inline ul-
trasonic flowmeter provided the liquid is
essentially clean and bubble-free
For gas or steam applications a vor-
tex meter is the normal choice Using a
built-in temperature sensor a two-wire
loop-powered vortex meter can calculate
mass flow of saturated steam using in-ternal steam tables An external pressure
input allows mass flow of steam to be ac-
curately calculated even when saturated
steam becomes superheated as can oc-
cur downstream of a pressure regulating
valve With mass flow known the vortex
meter can calculate energy and heat flow
A new and exciting development is
the ability of the vortex meter to indicate
wet steam and calculate dryness frac-
tion or steam quality For safety and ef-
ficiency saturated steam should be dry
and free from condensate that is to say
it should possess a high steam quality
factor However the dry or wet state of
saturated steam can sit on a knife-edge
and shift to the opposing state due to
the slightest change in process condi-
tions Rapid and reliable indication of
this change of state is now available
Perhaps the most astonishingachievement in the power management
of two-wire loop-power flowmeters is
that of the ultrasonic biogas meter It is
now possible not only to measure the
flow of wet dirty variable composition
and low-pressure anaerobic digester
gas landfill gas and coal bed methane
gas with a two-wire loop-powered ultra-
sonic flowmeter but also the same de-
vice uses an inbuilt temperature sensor
in combination with measured sound
velocity to calculate methane contentcalorific value and energy flow
Technology to Take UsForwardModern flow technologies provide instru-
ment engineers with vital self-monitoring
information The format of such infor-
mation is easier to understand and act
upon when presented in accordance
with harmonized international guidelines
for online plant asset management eg
NAMUR Standard 107
Continuous plain-text self-diagnostic
and process-related information with
suggested remedies (Figure 3) make it
possible for instrument engineers andoperators to take action at the appro-
priate time mdash immediately or during
the next scheduled shutdown mdash saving
time and money by knowing the exact
health of their measuring point and the
probable actions required to rectify any
abnormal conditions Device verifica-
tion offering third-party validated trace-
ability can be performed on demand ei-
ther locally or remotely from the control
room without the expense of a man in
the field Calibration is then avoided ordeferred without process interruption
Where a process plant has a large
installed base of older mechanical tech-
nologies the decision to embark upon a
program of replacement for plant mod-
ernization cannot of course be taken
easily There are the stocks of spare
parts to consider along with the plant
instrument technicians who are trained
on and at ease with the old devices
However a process plant that retains
the older technology going forward willbe at risk and may find it increasingly
difficult or even impossible to maintain
a cost position that competes effective-
ly in the global market FC
wwwusendresscom
wwwflowcontrolnetworkcom January 2015 | 19
Steve Milford
is a Flow Product
Business Manager
for Endress+Hauser
Inc in Greenwood
Ind He has been
involved in flow
measurement since
1983 and has been
actively involved with standards devel-
opment for flow technology within the
International Standards Organization
(ISO) and the British Standards
Institute Mr Milford can be reached
at stevemilfordusendresscom
Steve Milford
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Coriolis Flowmeter | Magnetic Flowmeter | Two-Wire | Ultrasonic Flowmeter | Vortex Flowmeter
Figure 3 A modern instrumentrsquos display module can provide continuous plain- text self-diagnostic and process-related information
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2345
The bottom line is the volume of gas under one set of
pressure and temperature conditions is not the same as it
would be for the gas under different conditions Why is thisimportant Without compensation for compressibility read-
ings taken by gas flowmeters can result in measurementsmdash
and costs to the buyermdashsignificantly lower or higher than they
should be
The flow of gas in a system can be accounted for and
reported in a number of ways such as by volume by mass
flowrate and by energy Inline turbine meters can offer both
reliability and accuracy in measuring gas flow when matched
with a monitor capable of calculating and displaying results
that have been adjusted for the nature of the gas and impor-
tantly the pressure and temperature
Measuring Flow with an Inline TurbineFlowmeter
With an inline turbine meter gas flows into the meter through
a length of piping that helps to pre-condition the flow by
reducing undesirable swirls and asymmetry Where consid-
ered necessary a flow straightener may even be installed in
line to create a uniform flow profile to the extent possible
As can be seen in Figure 1 a rotor support within the tur-
bine housing further conditions the flow and directs it through
the blades of the rotor High-precision ball bearings allow the
rotor to freely rotate on the shaft
The rotorrsquos rotational speed is directly proportional to the velocity of the fluid passing through the meter The rotor itself
incorporates magnets (or magnetic blades depending on thedesign) while the housing is non-magnetic
A proximity sensor (also known as a pickup coil) is located
in line with the rotor and detects the electrical pulses gener-
ated by the ferrous rotor spinning through the magnetic field
Each pulse represents a discrete volume of gas The out-
put frequency provides the indication of the gas flow rate and
the accumulated pulses over a specified time represent the
total volume of fluid for that measurement period
Need for Calibration The flowrate of the gas through the meter cannot be deter-
mined accurately unless the meter is calibrated The fac-tory calibration determines the meterrsquos constant known
as a K-factor which is then inputted into the gas monitor
PPLICATION NOTES | Flow Measurement
20 | January 2015
Flow Control Magazine
COMPENSATING for
Compressibility inMeasuring Gas Flow Why K-factor adjustment is essential foraccurate inline turbine flow measurement
Unlike crude oil and other liquid fossilfuels natural gas poses a challenge
in monitoring the quantity of gas flowing
through pipelines While liquids do not com-
press gases do and the mass flowrate of
gas being transmitted through gathering
lines depends on both the pressure and
temperature
By Kevin Clark
Figure 1 Internal components of a liquid turbine flowmeter
C O U R T E S Y
T U R B I N E S
I N C
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2445
Wondering Whether the
Pump Guy Seminar
Is for YouCheck out the ldquoPump Guy Insightsrdquo
video series flwctrlcompginsights
PUMP GUY INSIGHT 1NPSHa vs NPSHrmdashWhy all pumps need gauges
PUMP GUY INSIGHT 3How to Operate Your Pump at Best Efficiency
PUMP GUY INSIGHT 5Head vs Flow
PUMP GUY INSIGHT 2 Your Pumps Are Constantly Moving On Their Curves
PUMP GUY INSIGHT 4 The Role of the Pump Reliability Chain
PUMP GUY INSIGHT 6How to Read a Pump Curve
PARTNER SPONSORSFor more information and to register
for upcoming Pump Guy Seminars
visit FlowControlNetworkcomPumpGuy
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2545
PPLICATION NOTES | Flow Measurement
22 | January 2015
Flow Control Magazine
Gas flowmeters measure the actual volume of gas passing
through the meter per minute irrespective of pressure and
temperature1
The volumetric flowrate of a gas is often corrected to
ldquostandardizedrdquo conditions of pressure and temperature While
ldquostandardrdquo conditions can vary depending on the definition
in the US this typically means a pressure of 1473 PSIA(pounds per square inch absolute) and a temperature of 60 F
The flowrate measurement is reported in standard cubic feet
per minute (SCFM)
Compensating for changes in pressure and temperature is
critical Consider a meter system setup for flowing conditions
of 60 PSIG (pounds per square inch gauge) and 60 F and the
line pressure decreases to 50 PSIG while the temperature
remains constant The difference in SCFM between the two
is more than 15 percent which would cost the buyer more
for the gas than it should As Table 1 demonstrates even a
small variation in pressure will result in a surprisingly high er-
ror percentage
Automation of the K-Factor The K-factor is established by an initial factory calibration In
the case of a non-compensated flow monitor any variations
in pressure and temperature will result in manual adjust-
ments needed to the K-factor In order to maintain accurate
flow measurement users must monitor pressure and temper-
ature and make corresponding adjustments to the K-factor To eliminate these manual adjustments some suppliers offer
a flow monitor that automatically adjusts for any changes in
pressure and temperature
These monitors provide accurate flow measurement regard-
less of changing environmental conditions in some cases sup-
porting applications with pressures as high as 15000 PSIG and
temperatures between -350 F to 350 F with a standard accura-
cy of +-1 percent over a flow range of 05 ACFM to 650 ACFM
Final NotesDuring the operation of a flowmeter system the ability to obtain
a readout mdash and to adjust for line pressure and temperaturechanges mdash is sometimes compromised by a lack of electric
power This issue is especially true along gas pipelines in remote
areas To overcome this limitation some manufacturers have
designed low-powered flow monitors which can operate for up
to on year on a single lithium D-cell battery
It is important for users to recognize the effects of the
compressibility of gas As such the quantity of a gas flow-
ing through a gas flowmeter depends on the pressure and
temperature In order to ensure accuracy any flowmetering
system must employ a means to correct for these effects
Otherwise the readout is certain to be in error and could be
unnecessarily costing money This is particularly crucial onwellhead production and in billing scenarios FC
wwwturbinesincorporatedcom
Notations1 The measurement factor in the US is known as the
ACFM actual cubic feet per minute (Metric units are typically
ACMH actual cubic meters per hour)
Table 1 Error induced by line pressure changes
Constant Temperature with Varying Pressure
Pressure Temperature PulsesSCF Error
50 60 2556027821 1546
51 60 2517123288 1370
52 60 2479385307 1199
53 60 2442762186 1034
54 60 240720524 873
55 60 237266858 717
56 60 2339108911 566
57 60 2306485356 418
58 60 2274759285 275
59 60 2243894166 136
60 60 2213855422 000
61 60 2184610304 132
62 60 2156127771 261
63 60 2128378378 386
64 60 210133418 508
65 60 2074968632 627
66 60 2049256506 743
67 60 2024173807 857
68 60 1999697703 967
69 60 1975806452 1075
70 60 1952479339 1181 Flow Measurement | K-Factor | Measurement
Accuracy | Turbine Flowmeter
Find related content flowcontrolnetworkcomhellipSearch on
FLOWSTREAM
Kevin Clark is senior develop-
ment engineer for Turbines Research
amp Development LLC Turbine RampD is a
subsidiary and the research and techni-
cal support arm of Turbines Inc which
serves a range of industries and applica-
tions from oil amp gas to cryogenic liquids
to custody transferKevin Clark
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2645
Pumps Bearings amp Seals TECHNOLOGY REPORT
FEATURES
SYSTEMS DESIGN
The ComplicatedCase of
Compressors
withSide-Streams
24 28 32BEST PRACTICES
How PumpingSystems
AffectSealing
Performance
TECH OUTLOOK
BearingSuppliers
Drive Gains InDeveloping
Markets
wwwflowcontrolnetworkcom January 2015 | 23
S P E C I AL S E C T I O N
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2745
The design and operation of compressors with side-
streams has always been difficult because flow entering the
compressor needs to be mixed with the core flow already
in the compressor (compressed in section-1) in a manner
that does not degrade the aerodynamic performance of sur-
rounding sections Minimizing losses and ensuring proper
mixing of the side-stream flow and core-flow are required to
ensure effective performance of a compressor of this sort
Key considerations for an application involving compres-
sors with side-stream flow include
The plant process typically dictates the side-stream
flange pressure
The impellers upstream of the side-stream should
achieve the necessary pressure for the core-flow
The side-stream flow is typically at a temperature dif-
ferent from compressor core-flow temperature
Process plants need some degree of operational flex-
ibility ie the ability to support variations in core-flow condi-
tions and side-stream conditions
Modern process plants are usually specifying more than
one operating conditions (sometimes two or more manda-
tory conditions) which can present challenges to compres-
sors with side-streams Adding to these issues modern
compressors should operate with much higher impeller tip
The COMPLICATED CASE ofCompressors with Side-StreamsConsidering key system design requirements
to ensure operational efficiency By Amin Almasi
4 January 2015
Flow Control Magazine
|
y
g
Some compressors in certain applications
have one or more incoming side-streams
(or side-loads) that introduce side-stream
flow to mix with the core flow In other words
a radial side-stream inlet is utilized in multi-
impeller centrifugal compressors to introduce
additional gas into the mid-stage of a com-
pressor This design enables optimization in
some process plants However the flow dis-
tribution after the junction of the side-stream
and the main return channel of the upstream
section can significantly affect the perfor-mance of the next section of compressor
In most cases the pressure levels at these
side-streams should be accurately predicted
to meet the theoretical performance
Compressor station at a natural gas processing plant
R U D M E R Z W E R V E R I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2845
speeds and inlet Mach numbers compared to previous
generations of compressor technology
Likewise side-streams are now com-
monly used with medium-sized and
large-sized compressors (eg 1ndash60
MW) The costs associated with cor-
rections on side-stream compres-
sor applicationsmdashany repair
inefficient operation and power
lossesmdashwould be very high Fur-
ther compressors with side-streams
are usually sensitive and difficult
machines to operate In particular
performance curves (performance
pressures efficiency etc) are sen-
sitive to suction inlet conditionsside-stream inlet conditions vol-
ume flow ratio (side-stream vol-
ume to core-flow volume) and side-stream losses
Compressors with side-stream often perform far below
expectations The main reason is that side-stream compres-
sors are different than conventional compressors (without
a side-stream) in design and operation For a compressor
with side-streams tighter tolerances in operating conditions
must be identified and applied Uncontrolled variations of
suction pressure or side-stream pressure are major prob-
lems Another major issue is the variations of the flow ratio
(side-stream flow to core-flow)
Compressor Side-Stream amp Mixing SectionIn many centrifugal compressors the portion of the side-
stream system from the flange connection to the mixing
section is similar to a compressor inlet A great challenge
is ensuring the mixing section provides circumferentially
uniform merged-flow with minimum losses This can be
achieved via effective design of the inlet configuration and
mixing section of the side-stream compressor such that
the impeller can be maintained over the whole operating
range of the compressor In many cases while there are
mixing sections provided for the machine the flows do not
completely mix before entering the impeller of the section-2
(the impeller after the mixing section) Non-uniformity at
inlet flow to the impeller is a key concern for compressor
performance
Another consideration is a compact design of the side-
stream mixing section Specifically a mixing section with
less axial length is always preferred This axial length can af-
fect the compressor rotor dynam-
ics the rotor length and over-
all compressor performance
(design cost operation and
reliability)
The side-stream exit pressure
(side-stream pressure at inlet
of the mixing section) is mainly
a function of the side-stream
flow velocity and the pres-
sure in the previous section of
the compressor Conversely the side-
stream flange pressure can depend on
side-stream flow velocity and section-1
exit conditions Therefore the side-stream
inlet flange volume flow is a function of theflange pressure compressibility (at that
pressure and temperature) and mass flow
Some engineers assume that the side-stream flange pres-
sure is equal to the inlet pressure of the first impeller of the
section-2 This is not true The mixed total pressure can be
estimated on a mass-averaged basis using side-stream total
pressure and return channel exit (section-1) total pressure
In some designs because of the lower static pressure at
the side-stream exit the total pressure at the return channel
exit is lower even though the velocity upstream is roughly
matched for both streams The pressure usually increased
at the returned channel but it can be reduced again at the
side-stream exit While simple in nature this can have an
impact on the prediction of pressure at the side-stream exit
and overall mixing section performance Based on basic flow
principles it was usually assumed that the static pressure
was equal between both flow streams at the mixing location
While this assumption might be used in rough calculations
the accurate simulations have shown this assumption is not
true In fact there are some points (for instance the shroud
wall at the exit of the return channel and the hub wall at
the exit of the side-stream) where this assumption is true
However this is not valid for all locations There are pressure
changes that occur from a side-stream flange to the inlet
of the next section (section-2) which depend on different
factors The first factor is the frictional losses due to side-
stream geometry from side-stream flange to plenum mix-
ing section etc The other factors are pressure changes due
to local curvature and geometry details of mixing section
Another consideration is the operation of a compressor
with side-stream at part-load The performance of the side-
wwwflowcontrolnetworkcom January 2015 25
Figure 1 An example of a centrifugalcompressor with side-stream
COURTESY SIEMENS
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 29456 January 2015
Flow Control Magazine
|
y
g
stream path the mixing section and
the downstream impellers when ma-
chine is operated at part-load or even
off-design operating flows will result
in additional compressor performance
problems In such a case both veloc-
ity profiles and pressure variations in
various parts (side-stream path mixing
section etc) will be different resulting
in complicated flow patterns and com-
plex aerodynamics behaviors
Side-Stream CompressorSectional Performance
Typically vendor-supplied compressor
performance curves reflect flange-to-flange performance because that is
what the plant engineers need to
evaluate the proper operation of their
system (for example from suction to
side-stream and from side-stream to
discharge) In many cases compres-
sor vendors also provide the over-
all compressor performance curves
and performance curves for section-1
(from suction to side-stream) and sec-
tion-2 (from side-stream to discharge)
Flange-to-flange data if not interpret-
ed properly can lead to false conclu-
sions about the relative performance
of individual sections of a compression
system For example if side-stream
losses from the flange to mixing sec-
tion are attributed to the downstream
section (section-2) it will cause the
downstream section (section-2) to
appear low in performance while the
upstream section (section-1) will show
high performance levels
An important behavior to con-
sider is when the actual side-stream
pressure is different than the rated
side-stream pressure When the side-
stream pressure is slightly higher than
the outlet pressure of the section-1
it (section-1) shows a relatively higher
performance compared to the real sec-
tion-1 performance In some cases
the performance of section-1 could be
considerably higher than section-2 In
other words when performance is de-
termined flange to flange the higher
flange pressure is seen as extra ldquopseu-
dordquo work done by the section (since this
is an inconsistent thermodynamic vol-
ume) resulting in a relatively high sec-
tional efficiency (section-1 shows a rel-
atively high efficiency) This is the case
for many compressors with side-stream
because the whole system is designed
(or specifically the side-stream location
is selected) in a way aimed at main-
taining the real side-stream pressure(side-stream inlet) above the section-1
outlet pressure because if the real side-
stream pressure becomes lower than
the section-1 outlet pressure the flow
may (theoretically) reverse
This is particularly important when
the side-stream mass flow is much
lower than the mass flow of core-flow
The above-mentioned reasons explain
why in many simulations calcula-
tions and performance reports related
to compressors with side-stream the
section-1 shows a relatively good ef-
ficiency and section-2 appears low in
efficiency
When the side-stream pressure is
slightly lower than the outlet pressure
of the section-1 the section-1 might
show a relatively lower performance
compared to section-2 This could oc-
cur in some recycle services where the
side-stream is actually a recycle flow
with a mass flow around two to five
times the core-flow The side-stream
(recycle) flow is returned from down-
stream of the compressor to be slightly
compressed and recycled to the down-
stream Such a recycled side-stream
compressor can present unique chal-
lenges for design and operation This
kind of machine usually needs very
special operating procedures and very
fine adjustments regarding operating
pressures and flows
Side-Stream Compressor
Performance amp Operation An important consideration is the sen-
sitivity of compressor overall perfor-
mance curve and sectional perfor-
mance curves to the flow ratio (ratio
of side-stream flow to core-flow) and
to the inlet conditions Variations in
the flow and pressure of the main
suction and side-stream inlet should
be controlled within tight tolerances
For compressors with side-stream the ASME PTC-10 code stipulates limits on
flow ratio (side-stream volume to core-
flow volume) The acceptable variation
in volume flow ratio in a compressor
with a side-stream is +-5 percent as
per ASME PTC code The requested
side-stream pressure tolerance is not
usually specified in compressor codes
but it should be around +- 2 percent
(or sometimes +- 25 percent)
Variance in flow ratio impacts the
velocity levels where the two streams
merge Significant variation in the ve-
locity profile upstream of the impeller
changes the incidence on the blade
leading edge of the following impel-
ler This change in incidence leads to a
change in sectional performance over-
all compressor performance and train
efficiency
If the flow ratio is varied between 95
percent and 105 percent (tolerances
specified in the ASME PTC-10 code)
the flange pressure changes accord-
ingly resulting in a change in the sec-
tional performance and overall perfor-
mance The sectional efficiency varies
sometimes more than +- 4 percent
This variance reduces as the flow is de-
creased toward surge However as the
flow is increased toward overload the
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3045wwwflowcontrolnetworkcom January 2015 27
variance increases up to higher values
(even in some cases three to five times
compared to variations near the surge
zone) For example in a case study
for a compressor with side-streams a
+- 5 percent variation in flow ratio and
associated changes (pressures losses
etc) the sectional efficiency reduced by
approximately 34 percent at the rated
flow at allowable operating points at
the end of curve (near the overload
ie choke) efficiency reduced by ap-
proximately 55 percent These results
show that the variation in sectional
performance and overall performance
due to flow ratio is highest at operat-ing points near the overload and low-
est at operating points near the surge
For compressors which work most of
the time at high flow (flow higher than
rated flow and discharge pressure low-
er than rated pressure) the effects of
flow ratio deviations (and subsequently
efficiency reduction) would be higher
than compressors working on the left-
hand side of curve (say with sufficient
margins near the surge)
In the compressor codes (such as
API 617) the compressor power varia-
tions should be maintained below 4
percent However in some applica-
tions clients require tighter tolerances
on the consumed power sometimes
below 2 percent (or even below 15
percent) Some studies suggest while
+- 5 percent of volume flow ratio is
suitable for performance test as per
ASME PTC-10 code some plants re-
quire tighter control on the consumed
power and compressor performance
(lower limits on the efficiency) the tol-
erances on the volume flow ratio could
be tighter than ASME PTC code In this
regard +- 4 percent tolerance can be
suggested on the volume flow ratio (ra-
tio of side-stream flow to core-flow) of
compressors with side-streams
Based on operational experiences
acceptable variations in volume flow
ratio and inlet pressures (suction inlet
and side-stream inlet) of a compressor
with side-streams are +- 4 percent
and +- 2 percent respectively
Another important consideration is
the required adjustments for the flow
ratio (side-stream flow to core-flow)
Compressors with side-stream usually
require fixed side-stream flange pres-
sures For a compressor with some variations in operation conditions (even
small changes) it is not usually pos-
sible to achieve optimum operation by
keeping the flow ratio (side-stream to
core-flow) constant The flow ratio has
to be adjusted according to the inlet
flow at which the machine is operating
in order to get the required correspond-
ing side-stream flange pressure
Thermal changes have also been
known to cause some instability in
centrifugal compressors An example is
the thermal-induced change of resid-
ual unbalance For compressors with
side-streams which feature tempera-
ture differences between core-flow and
side-stream flow the thermal behav-
ior of the compressor is usually more
complex and requires more attention
Heavy Gas ChallengeHeavy gases (such as heavy hydrocar-
bon gases eg propane propylene
MTBE (Methyl Tertiary Butyl Ether))
have very low gas sonic velocities that
produce high Mach numbers in the
aerodynamic flow paths For these
services because of high Mach num-
ber high flow coefficient stages have
very narrow flow maps characterized
by limited surge and choke margins
Compressors with side-streams in
these services present great challeng-
es This is to say the side-streams and
associated mixing further complicate
design operation and performance
prediction because the pressure tem-
perature and flow conditions at each
one of these side-streams as well
as at the exit of the machine require
stringent tolerances to optimize the
overall efficiency and performance
As such it is important to accuratelymodel design operate and moni-
tor performance characteristics of any
impellers diffusers return channels
and generally all flow-path components
in a compressor with side-stream FC
Amin Almasi
is a senior rotating
machine consultant
in Australia He is
a chartered profes- sional engineer of
Engineers Australia
(MIEAust CPEng ndash
Mechanical) and
IMechE (CEng MIMechE) holds
bachelorrsquos and masterrsquos degrees
in Mechanical Engineering and is
a registered professional engineer
in Queensland He specializes in
rotating machines including cen-
trifugal screw and reciprocating
compressors gas turbines steamturbines engines pumps subsea
offshore rotating machines LNG
units condition monitoring and reli-
ability Mr Almasi is an active mem-
ber of Engineers Australia IMechE
ASME and SPE He can be reached
at aminalmasiymailcom
Amin Almasi
Compressor | Gas Flow | Performance Curve | Side-Stream Flow
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3145
The pressure in the stuffing box
containing the packing can be estimat-
ed by the following equation
SBP = [Discharge ndash Suction] 3 + Suction
Pressure at the bottom of the stuff-
ing box will be higher than the suction
pressure but considerably lower than
the discharge pressure It should be
noted this calculation will yield a con-
servative estimate of stuffing box pres-
sure that can be further reduced by
pump design
A hole in the stuffing box serves as
a port for injecting clean fluid that cir-
culates around a lantern ring aligned
under the flush port The fluid flushes
solids back into the process to protect
the packing from abrasive wear If the
clean fluid is injected at a pressure ex-
ceeding that at the bottom of the stuff-
ing box some of it will leak back into
the process and some will leak out to
the atmosphere Recommended flush
injection pressure is 15ndash30 PSI (1ndash2
Bar) greater than the pressure at the
bottom of the stuffing box
Fluid injection is also used to lubri-
cate and cool dry-running packing that
is subject to frictional heat and to pre-
vent air from entering the pump which
reduces flow and operating efficiency
Centrifugal pumps utilize three
types of impellersmdashopen semi-open
and closed (Figures 2 3 amp 4) Open
designs prevent fluids with large solids
from clogging the impellers but at theexpense of pump efficiency Backing
plates on semi-open designs serve to
trap the fluid for more efficient opera-
tion Closed impellers are for use with
clean fluids since solids could ac-
cumulate in the eye which would re-
quire tearing down the pump to remove
them
Single-Stage CentrifugalPumpsSingle-stage centrifugal pumps typi-
cally have good bearing support of the
shaft with few run-out or ldquowhiprdquo prob-
lems However in some cases they
are subject to cavitation This occurs
in the eye of the impeller where the
fluid is under vacuum If the pressure
is low enough it will cause the material
to vaporize forming air or water vapor
bubbles As the fluid passes through
How Pumping Systems Design Affects Sealing Performance
By Chris Boss
8 January 2015
Flow Control Magazine
|
Understanding how different types of pump designs impact
sealing is critical to optimizing efficiency safety and lon-
gevity of the sealing system Used for a wide variety of media
including clear fluids solutions and slurries single-stage
centrifugal pumps are one of the most common
types (Figure 1) Fluid drawn into these pumps
enters the eye of an impeller that spins itto the outside of its container
or volute building pressure as
it moves toward discharge
Some of this fluid will work
its way behind the impeller
where it must be sealed with
compression packing or a
mechanical seal
Figure 1
Figure 2 Figure 3 Figure 4
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3245
the pump under increasing pressure
these bubbles implode sending shock
and vibration through the impeller
adversely affecting the seal This phe-
nomenon can be mitigated by running
the pump at slower speed and higher
pressure at the suction end to prevent
air from entering the fluid
Double-Ended Split-CasePumpsOperating on the same centrifugal prin-
ciple but slightly different geometry are
double-ended split-case pumps (Figure
5) Fluid enters both ends of the pump
and is directed into the eye of an impel-ler which spins it out of the volute to
discharge Packing is installed on both
the shaft and bearing ends so the stuff-
ing box is exposed only to suction pres-
sure which is usually quite low
Axial Flow Pumps Axial flow pumps operate like hydro
turbines in reverse whereby a propeller
(or axial impeller) pushes the fluid to
discharge (Figure 6)
Since the stuffing box is located
downstream of the propeller at the dis-
charge end of the pump the packing is
exposed to the full discharge pressure
Vertical PumpsVertical turbine pumps are typically
flange-mounted on a floor extending
downward into a water-filled sump
hole (Figure 7) Available as single- or
multi-stage pumps they feature an
impeller or series of impellers rotated
simultaneously by a single shaft The
impellers increase the pressure of the
upward flow subjecting the stuffing box
to full discharge pressure
Vertical pumps can be quite long so
inadequate bearing support can cause
the shaft to run out This can induce
undesirable lateral motion on the pack-
ing Worse the packing may be forced
to serve both as a bearing and a seal To
withstand these conditions the packing
should be resilient elastic and resistant
to deformation These properties rule
out packing such as graphite foil in favor
of fiber-based materials
Multi-Stage PumpsMulti-stage pumps are used for high-
pressure applications such as feeding
the boilers in steam-powered generating
plants Stuffing box pressure can vary
with pump design and number of stag-
es Designed for clean fluids and high
operating speeds these pumps typically
have high- and low-pressure ends with ahydraulic pressure equalization line run-
ning between the stuffing boxes
Like vertical pumps multi-stage
pumps feature a series of impellers to
build fluid discharge pressure In the
case of the six-stage pump pictured in
Figure 8 fluid enters at the drive end
where a stuffing box is exposed to suc-
tion pressure Channeled from one
impeller to the next through the pump
casting the fluid can reach extremely
high pressures at discharge
A second stuffing box located at the
bearing end is exposed to an intermedi-
ate pressure from the third impeller This
pressure is greater than the suction pres-
sure but much less than the discharge
pressure which can reach 2000 PSI
Fortunately the stuffing boxes in
these pumps are not exposed to dis-
charge pressures and typically see be-
low 500 PSI which is within the range
of some packing materials
wwwflowcontrolnetworkcom January 2015 29
Figure 5
Figure 6
Figure 7
Figure 8
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 33450 January 2015
Flow Control Magazine
| Gear PumpsPositive-displacement or gear pumps
operate on a different principle than
centrifugal pumps In external gear
pumps the fluid flows around the out-
side of the gears the intermeshing
of which forces it through the pump
to discharge (Figure 9) This design
makes these pumps particularly suit-
able for use with highly viscous fluids
such as resins emulsions syrups and
adhesives As such they are used for
transfer or metering applications
It should be noted gear pumps will
continue to displace fluid as long as
their shafts are turning which can pose
a problem if a clog occurs at the dis-
charge The resulting buildup of pres-
sure can blow out seals and damage
the pump Therefore most gear pumps
have pressure relief valves to divert
fluid back to the suction side for re-
circulation through the pump Internal
gear pumps operate slightly differently
but also have pressure relief valves to
prevent damage from excessive pres-
sure (Figure 10) In both external and
internal gear pumps the maximum
stuffing box pressure is determined by
these valves
Other rotating equipment includes
mixersagitators which are similar to
pumps in terms of the speeds to which
the packing is exposed There are ba-
sically three types of mixersagitators
top- bottom- and side-entry Top-entry
models are subject to the same con-
cerns about shaft run-out ldquowhiprdquo and
lateral forces on the paddles that are
encountered in some vertical pumps
Although some fluid may splash onto
the packing these mixers basically run
dry so the packing must have the abil-
ity to dissipate the resulting frictional
heat
In bottom-entry mixers the packing
is always exposed to fluid and may also
be exposed to solids requiring abra-
sion-resistance If the seal fails the en-
tire contents of the tank will eventually
drain out onto the bearings the floor
and other components under the stuff-
ing box
The packing in side-entry mixers may
be fully or intermittently exposed to flu-
id as well as side loading and vibration
Aside from media temperature
speed and other application variables
the configurations and operating prin-
ciples of rotary-type pumps exert differ-
ent forces on the seals used to keep
them from leaking These forces can
spell the difference between accept-
able seal performance and failure
Understanding these differences has
important implications that should be
taken into account to assure proper
sealing selection for long-term trou-
ble-free performance FC
wwwgarlockcom
Chris Boss is
a senior applica-
tions engineer for
Garlock Sealing
Technologies in
Palmyra NY He
has held various
positions in produc-
tion engineering
product development and applica-
tions engineering for the companyrsquos
compression packing division He
is a BSME graduate of the State
University of New York at Buffalo Mr
Boss can be reached at 800 448-
6688 or chrisbossgarlockcom
Chris Boss
Cavitation | Centrifugal Pump | Pump Packing | Sealing System
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Figure 9
Figure 10
Aside from media temperature speed and
other application variables the configurations
and operating principles of rotary-type
pumps exert different forces on the seals used
to keep them from leaking These forces can
spell the difference between acceptable seal
performance and failure
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3445
NS IDERNDUSTRIAL AUTOMATION + PROCESS CONTROL
WANT
INFORMATION
ON THE
automationindustry
SUBSCRIBE NOW at wwwiainsidercouk
Published by Spitzer and Boyes LLC Write in 15 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3545
Frost says the push from developing
economies is important as the market
is technologically mature and seeing
restricted growth in developed econo-
mies This is particularly true in Europe
and North America where recent finan-
cial insta-
bility has
reduced capital expenditure across end-
user industries
Bill Moore senior vice president of
sales development and channel man-
agement for global bearings manufac-
turer SKF says ldquosmartrdquo products and
the expansion of robust reliability pro-
grams are helping to drive new invest-
ment particularly in developed coun-
tries where the cost to compete is
high Frost says the magnitude of
the existing global installed base will
strengthen the need for replacement
and upgrades adding to market de-
mand as well
Frost says despite the potential
in developing economies the focus
on price as a product differentiator
may lead to intense price pressures
among manufacturers and bring down
the value of the overall market in the
short term The growing trend among
consumers to choose low-cost Chinese
imports will complicate this challenge
As price and quality become stan-
dardized across the globe customers
will base more of their purchasing deci-
sions on value-added services accord-
ing to Frost This will push manufactur-
ers to create more maintenance-free
solutions such as lubrication-free
bearings that offer end-users savings
on service and replacement costs and
reduce downtimeldquoOffering a complete line of prod-
ucts with comprehensive services will
be another feather in the cap of ven-
dors looking to widen their consumer
baserdquo notes Frost Industrial Automa-
tion and Process Control Research
Analyst Guru Mahesh
Moore says the trend of outsourcing
manufacturing to regions where labor
and production costs are favorable is
becoming less of a factor
ldquoThe days when cheap labor made
a significant difference in where a prod-
uct is manufactured mdash particularly high
value-added products or high weight
and bulk products mdash are coming to
an end as the cost of transportation
storage and inventory balance out the
benefits of production costs where la-
bor is a smaller percentage of the cost
of manufacturingrdquo Moore says ldquoLocal
manufacturing development will indeed
come to developing countries as their
ability to create markets that generate
economies of scale that support local
production is a clear trend and one that
all manufacturers will pay attention tordquo
Moore says that development of
maintenance-free or predictive tech-
nologies and products will be a sig-
nificant advantage to everyone in the
Bearing amp Coupling Manufacturers Focus
onDEVELOPING Economies
amp EFFICIENCY InnovationBy Amy W Richardson
2 January 2015
Flow Control Magazine
|
gy
Anew study from Frost amp Sullivan (wwwfrostcom) fore-
casts steady growth for the overall bearings and couplings
market based on rapid industrial development in high-growth
regions Specifically Frost predicts development in Mexico
Indonesia Nigeria Turkey Brazil Russia India and Chinawill help boost the bearings amp couplings market from $2206
billion in 2013 to an estimated $2676 billion in 2018
The development of maintenance-freeor predictive technologies will helpboost growth in the bearings market For example SKF is developing products that will automatically notifyusers when a bearing or mechanicalrotating component is approachingthe end of its useful life Pictured hereis an SKF Microlog analyzer a por- table condition monitoring tool
COURTESY SKF
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
improved productivity through simplified solutions The powerful technology and tools ensure repeatable
reliable accurate measurements Easier access to process data allows for better troubleshooting process
optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
For daily product notes visit the lsquoFeatured Productsrsquo section flowcontrolnetworkcom
ON THE WEB
1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3845
FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
and benefits as well as grids of
instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
services provided for the
mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
Brought to you by Beamex
Your Source For Fluid Handling Videos
Go towwwflowcontrolnetworkcomfreeinfo
Select appropriate issue ofFlow Control Magazine
Select advertisements thatinterest you
Enter your email amp clickldquoSubmit Requestrdquo
1
2
3
4
PRODUCT
INFORMATION
ONLINE
Follow these 4 steps to receive freeproduct information from suppliers
FREE
FEATURED VIDEO How to Calibrate aPressure Measurement Loop
For more information about FlowTube
sponsor packs email FlowControlGrandViewMediacom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4245
THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
Name ________________________________________________________________
Title _________________________________________________________________
Company _____________________________________________________________
AddressCityStateZip __________________________________________________
______________________________________________________________________
Phone ________________________________________________________________
E-Mail ________________________________________________________________
One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545
![Page 7: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/7.jpg)
7232019 Flow Control January 2015
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1 9 9 5 - 2 0 1
51 9 9 5 - 2 0 1
5
20th20th january 2015 | Vol XXI No 1
4 | January 2015
Flow Control Magazine
departmentscolumns6 EDITORrsquoS FILE
4 flow things you need to know aboutthis month
14 APPLICATIONS CORNERa coriolis mass flowmeter providesa better solution
39 WORD SEARCH temperature measurement
40 QUIZ CORNER how to calculate orifice plate flow rate
Cover imagesFlowmetercourtesyEndress+HauserBackgroundiStock
8 NEWS amp NOTES api 624 valveemissions update intelligent features toboost desal pumps market hydraulic fractur-ing water treatment on the rise
34 UP CLOSE with Micro Motionrsquos Model5700 Coriolis Transmitter
35 NEW PRODUCTS
36 WEB RESOURCE FILE
38 ADPRODUCT INDEX
S I N C E 1 9 5 8
Itrsquos More than a Check Valve
Itrsquos a Check-All
When You Need Absolute Precision
CHECK-ALL IS THE ONLY CHOICE
Our spring loaded check valves are assembled
to your exact needs ensuring absolute precision
and reliability They work like they should Plus
most lead times are less than one week Thatrsquos
what makes Check-All the only choice
Get me a Check-AllManufactured in
West Des Moines Iowa USA515-224-2301 bull salescheckallcom bull wwwcheckallcom
Write in 4 or Request Info Ins tantly at wwwFlowControlNetworkcomfreeinfo Write in 5 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
Return on investment calculations for plant upgrade or new
plant construction projects may go through several iterationsbefore the trigger is finally pulled or indeed not pulledldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 845
The new Ultratrade 8c The capability and performance
your market demands
Copyright copy FMC Technologies Inc All Rights Reserved
FMC Technologiesrsquo Ultra 8c ultrasonic owmeter shares the advanced technology
of the next generation Smith Meterreg Ultra Series meters With its touchscreen
interface upgradable memory and high-speed processor the Ultra 8c provides
cutting-edge performance and diagnostic ability And with additional measurement
paths the Ultra 8c has even better cross-ow and swirl compensation for improved
accuracy and repeatability Whether for leak detection or custody transfer theUltra 8c gives you the assurance of superior performance in the eld even for the
most viscous crude oils in todayrsquos market
For more information visit wwwfmctechnologiescomultrafc
wwwfmctechnologiescom
Write in 6 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 945
20 Years of Flow Control This
year marks the 20th Anniversary of
Flow Control magazine Launched
in 1995 with the aim of serving technical
professionals involved with designing oper-
ating and maintaining fluid handling systems in a wide range of
industries Flow Control has leveraged its many years of experi-
ence to establish a unique niche and reputation for providinghigh-quality information to you our subscribers I congratulate everybody who helped
Flow Control get to where it stands today Herersquos to another 20 years of success
Training Time Itrsquos a new year and we have two new
training opportunities for
you to enhance your skillset in 2015
Regular Flow Control columnists Da-
vid W Spitzer and Larry Bachus will
be presenting three-day courses on
Flow Measurement and Pumping
Systems respectively I encourage you and your colleagues to take ad-
vantage of these important training
opportunities For more details see
flwctrlcomflowseminar amp
flwctrlcompumpguy
Oil amp Gas Gender Gap Results of a
new global workforce survey conduct-
ed by OilCareerscom and Air Energi
show a gender gap in the oil amp gas industry
persists despite ongoing efforts to recruit more
women into the industry According to hiring
managers the
top three factors
that significantlycontributed to
the gender gap
in the oil amp gas
industry are
1 A lack of women entering the industry (55
percent)
2 An industry culture created by a male-domi-nated environment (53 percent)
3 The logistics requirement ie travel shift
and working patterns in the field (30 percent)
For more on this story and an infographic seeflwctrlcomog_gendergap
Rockwell Automation Fair 2014 Our colleagueKevin Parker at Processing magazine attended the
annual Rockwell Automation Fair Nov 9-10 in
Anaheim Calif Parker gleaned some interesting perspec-
tive on key trends in process automation including
1 Hardware and software are more blended than ever
2 Fog computing (a kind of cloud computing) is making
headway in industrial engineering environments where latency is a critical concern
For Parkerrsquos full report from the Automation Fair see flwctrlcomrockwellfair2014
DITORrsquoS FILE
6 | January 2015
Flow Control Magazine
4 Flow Things You Need to Know
GROUP PUBLISHERPROCESSINGFLOW CONTROL
MICHAEL C CHRISTIAN | (908) 507-5472mikecgrandviewmediacom
NATIONAL ACCOUNTS MANAGERJIM SEMPLE | (908) 963-3008 jsemplegrandviewmediacom
EXECUTIVE DIRECTOR OF CONTENTMATT MIGLIORE | (610) 828-1711
mattgrandviewmediacom
MANAGING EDITOR AMY W RICHARDSON | (205) 408-5050
arichardsongrandviewmediacom
COLUMNISTS
LARRY BACHUSDAVID W SPITZER JESSE YODER
ART DIRECTORJULIE FLYNN
juliegrandviewmediacom
MANAGER - DIGITAL OPERATIONSMARY BETH ROMANO
SUBSCRIPTION amp REPRINT REQUESTSflowcontrolhalldatacom
Administrative TeamGENERAL MANAGER
BARRY LOVETTE
CHIEF OPERATIONS OFFICERBRENT KIZZIRE
VICE PRESIDENT OF FINANCEBRAD YOUNGBLOOD
VICE PRESSIDENT OF B2B GROUPMIKE WASSON
CHIEF REVENUE OFFICERCHRIS DOLAN
VP AUDIENCE DEVELOPMENTDELICIA POOLE
AUDIENCE DEVELOPMENT MANAGER ANNA HICKS
DIGITAL AUDIENCEDEVELOPMENT ANALYST
STACY BARNES
EDITORIAL ADVISORY BOARDLarry Bachus Bachus Company IncGary Cornell Blacoh Fluid Control
Jeff Jennings Equilibar LLCMitch Johnson JMS SoutheastPeter Kucmas Elster Instromet
Jim Lauria Water Technology Executive
John Merrill PE EagleBurgmann IndustriesSteve Milford Endress+Hauser US Tom OrsquoBanion Emerson Process
Management Micro MotionDavid W Spitzer PE Spitzer and Boyes LLC
Tom Tschanz McIlvaine Company John C Tverberg Metals and Materials
Consulting EngineersJesse Yoder PhD Flow Research Inc
WINNER
WINNER WINNER
PERSPECTIVES FROM THE MONTH THAT WAS IN THE WORLD OF FLOW CONTROL
WINNER WINNER
THE
NETWORK
1
2 3
4
1 9 9 5 - 2 0
1 51 9 9 5
- 2 0 1 5
20th20th
Matt Migliore Executive Director of Content MattGrandViewMediacom
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1045
Endress+Hauser Inc
2350 Endress Place
Greenwood IN 46143
infousendresscom
ww wusendresscom
Sales 888-ENDRESS
Service 800-642-8737
Fax 317-535-8498
Guided wave radar level products - built for safety precision and efficiency
bull Reliable non-contact measurement even for changing process conditions
bull HistoROMreg data management - concept for fast and easy
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bull Multi-Echo Tracking evaluation - highest reliability even with the
presence of obstructions in the vessel
bull Hardware and software developed according to IEC61508 up to SIL3(in homogeneous redundancy)
bull Seamless integration into control or asset management systems
bull Worldrsquos easiest proof test concept for SIL saves time and cost
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The newest generation of Micropilot
Taking your process to the next level
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7232019 Flow Control January 2015
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HE OUTLOOK | News amp Notes
1 ISO15848 ldquoMeasurement test and qualification proce-
dures for fugitive emissionsrdquo
a Part I ndash ldquoClassification system and qualification proce-dures for type testing of valvesrdquo
b Part II ndash ldquoProduction acceptance test of valvesrdquo
2 API 622 ldquoType Testing of Process Valve Packing for Fugitive
Emissionsrdquo
3 End-user defined fugitive emission reduction requirements
Key aspects of valve testing per API 624 include
The standard covers rising and rising-rotating stem
valves up to 24rdquo diameter
Class 1500 valves are not covered
The test medium is methane
310 test cycles are required with three thermal cycles Temperature application range is from -29 C to 538 C
with last cycle 10 cycles user-defined (can be -45 C)
Re-tightening of gland bolts is not permitted during test
Valve stem test orientation is vertical
Several valves must be tested to achieve API 624 com-
pliance Similar industry principles applied to test valves
qualify two nominal sizes smaller one size larger and one
pressure class below
Allowable leakage is 100 PPM maximum
Gate and globe valves need to be tested separately
For example Gate Valves per API602 four tests API600
eight tests (up to 20rdquo diameter) API 603 eight tests andfor Globe Valves per API 602 four tests
Test valves should be production valves not specially
manufactured test valves
As a result of the release of API 624 testing companies have
been gearing up for an increase in the number and size of
test valves and new test houses are coming to market Withthis in mind implementation of API 624 needs to be carefully
monitored and claims from valve manufacturers should be
validated by requesting to view test results Important factors
to be mindful of include
Number of cycles on some valves could be detrimental
to packing as certain smaller size valves donrsquot come with
grease ports to keep the stem lubricated all of the time
Test failures of valve stem threads yokes and glands
Grease traps into packing and causes leakage
At higher temperatures a few greases create volatile
organic compound and burn off
Testing in vertical generates more heat in yoke area
Certain challenges need a good testing company that has
experience in testing on fugitive emissions and provides
guidelines to manufacturers in terms of use of packing valve
grease testing requirements etc
A preliminary survey was conducted with end-users regard-
ing current utilization and application of API 624 For a sum-
mary of responses from this survey visit flwctrlcom1oWijWz
Gobind Khiani PEng is with Fluor Canada Ltd Khiani has
spent 20-plus years in the energy and power business and 10-
plus years in the Western Canadian oil and gas industry Hecan be reached at 403 850-6982 or gobindkhianifluorcom
Valve Standards UpdateEnd-users ramp up compliance efforts for API 624
as new specifications emerge on the horizon
8 | January 2015
Flow Control Magazine
By Gobind Khiani
In the May 2014 issue of Flow Control (page
16) the new standard API 624 ldquoType Testing
of Rising Stem Valves Equipped with Graphite
Packing for Fugitive Emissions First Editionrdquo was
addressed This standard which was published
and put into effect in February 2014 estab-
lishes guidelines for testing industrial valves for
emissions compliance Since the publication ofthe May article further requests from industry
have spurred the creation of another specifi-
cation API 641 ldquoType Testing of Quarter-Turn
Valvesrdquo and an API ldquoPiping and Valvesrdquo commit-
tee has been formed Regulators and end-users
are also working on
1992 1998 2003 2008 2013 2020
4
35
3
25
2
15
1
05
0
M i l l i o n o f
t o n n e s y e a r Will API 624
have a stepeffect in reducing
fugitiveemissions
Global valve fugitive emissions
End User response at best
End User response actual
S O U R C E G O B I N D K
H I A N I
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1245
Intelligent Features to Boost Global WaterDesalination Pumps Market
The Global Water Desalination
Pumps Market is expected to grow
at a CAGR of 77 percent from 2015 to
2019 according to a new report from
TechNavio (wwwtechnaviocom)
The report shows demand for water
treatment has increased significantly in
developing countries where fresh wa-
ter resources can be scarce Providing
clean and potable water to huge popu-
lations has become a priority which is
pushing the demand for water desalina-tion pumps in the market according to
TechNavio
The report emphasizes the emer-
gence of intelligent pump systems as
a major driver of market growth In-
telligent pumps possess the ability to
regulate flow and pressure and these
systems can automatically adjust to
process and pump system changes
ldquoIntelligent pump systems are be-
ing adopted by many manufacturers
because of the high level of fault toler-
ance ability which leads to a significant
reduction in the total cost of owner-
shiprdquo said Faisal Ghaus vice president
of TechNavio in a news release ldquoThe
adoption of these systems will also
help industries comply with current Eu-
ropean Union regulations in relation toreduction in energy consumptionrdquo
The growing demand for clean wa-
ter worldwide will continue to augment
the demand for water desalination sys-
tems which will propel the Global Water
Desalination Pumps Market during the
forecast period
trendlines
wwwflowcontrolnetworkcom January 2015 | 9
Write in 8 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
Intelligent pump sys-tems are being adopt-
ed by many manufac-
turers because of the
high level of fault tol-
erance ability which
leads to a significant
reduction in the total
cost of ownership
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1345
HE OUTLOOK | News amp Notes
10 | January 2015
Flow Control Magazine
Hydraulic Fracturing WaterTreatment amp Reuse Expected to Soar
Wastewater treatment spending for
hydraulic fracturing is expected to
grow almost three-fold from $138 mil-
lion in 2014 to $357 million in 2020 in
the US according to a new report from
Bluefield Research
The US hydraulic fracturing industry
consumes over 1 billion barrels of wa-
ter annually producing 450ndash500 mil-
lion barrels of contaminated water for
disposal with only about 14 percent
treated and reused Bluefield cites watersupplies increasingly at risk tighter regu-
lations emerging in key states and costs
of disposal on the rise as factors con-
tributing to the substantial rise in water
treatment and reuse which is expected
to account for 27 percent of total pro-
duced and flowback water by 2020
Overall the US hydraulic fracturing
industry will spend $638 billion in 2014
on water management Water transport
and disposal costs will account for 66
percent of the total water managementspent this year with treatment compris-
ing roughly 2 percent
Bluefield reports water scarcity in
Western US states has had little im-
pact to date on fracturing water supply
but that is likely to change if droughts
persist Meanwhile state regulators are
beginning to tighten control of produced
water disposal In Pennsylvania where
policymakers in 2010 placed discharge
limits on wastewater from unconven-
tional oil amp gas operations statewide
treatment and reuse rates for the Mar-
cellus jumped to 90 percent in 2014
The increasing cost of transport and
injecting water into wells mdash now ac-
counting for 66 percent of water servicesspending mdash and the improving cost
structures of treatment provide another
driver of reuse Bluefield reports Well
operators that employ treatment and re-
use solutions spend on average $880
per barrel of water used compared to
$1020 per barrel of water trucked and
injected into wells although cost com-
parisons are site specific
ldquoFracking has been the Wild West for
the US water industryrdquo said Reese Tis-
dale president of Bluefield Research ina prepared statement ldquoThere are three
reasons for this first there has been
an explosive build-out of fracking well
installations now surpassing 126000
Second there has been a lack of clear
regulation on water management in key
markets And third there is not a one-
size-fits-all treatment solution for frack-
ing meaning solutions providers have
had to ascend a steep learning curve
to treat the variable wastewaters that a
single well is capable of producingrdquo
Tisdale notes that these inhibitors
while still acute are beginning to take on
a new form This is partially due to signifi-
cant gains in water management experi-
ence realized adoption of more efficientwater management strategies among
well operators and the emergence of
new policy mechanisms from regulators
that are playing catch-up with the fast-
moving hydraulic fracturing industry
trendlines
Treatment2
Disposal
6
Supply10
Storage22
Transport60
US $638Billion
S O U R C E B L U E F I E L D R
E S E A R C H
Write in 23 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
Industry-Leading
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Temperature Measurement Solutions
bull Probe type industrial RTDsbull Electronic temperature switchtransmitter bull Vapor-actuated remote thermometersbull Digital temperature indicatorsbull Platinum resistance temperature transmitterbull Compact OEM temperature transmitter bull Industrial amp instrument type bimetal thermometersbull Thermowells
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1445
New Technique Could ReduceEnergy Required for Oil Refinement
UK scientists have developed a
technique they say has the poten-
tial to dramatically reduce the amount
of energy required for the refinement
of crude oil
Professor Martin Schroumlder and Dr
Sihai Yang from The University of Not-
tingham (wwwnottinghamacuk ) have
led a multi-disciplinary team of scien-
tists from Nottingham the Science and
Technology Facilities Councilrsquos (STFC)
ISIS Neutron Facility Oak Ridge Na-tional Laboratory and Diamond Light
Source to discover a porous material
that works like a chemical sponge to
separate a number of important gases
from mixtures generated during crude
oil refinement
According to a news release from
The University of Nottingham the ex-
isting industrial process uses ldquohuge
amounts of energy to separate and pu-
rify these gases so the new technique
has the potential to revolutionize the oil
industry by significantly reducing car-
bon emissions and making the process
more environmentally friendlyrdquo
Commercially UsefulCrude oil is a raw material that is
refined to produce fuel for cars toheat homes and to create polymers
and other useful materials It is made
up of a complex mixture of hydro-
carbons (chemical compounds that
contain only hydrogen and carbon) of
which certain components are espe-
cially commercially useful
One industrial process used to
achieve hydrocarbon separation is
called ldquocryogenic distillationrdquo which is
widely used worldwide and uses vast
amounts of energy to generate the high
pressures and cryogenic temperatures
required to ensure efficient separation
research amp development
wwwflowcontrolnetworkcom January 2015 | 11
PLASTIC CONTROL VALVES FORALL YOUR CORROSIVE APPLICATIONS
PO Box 938 bull Angleton TX 77516Tel (979) 849-8266 bull wwwcollinsinstcom
Collins plastic control valves are
highly responsive control valves
designed for use with corrosive
media andor corrosive atmos-
pheres
Collins valves feature all-plastic
construction with bodies in PVDF
PP PVC and Halar in various body
styles from 12 - 2 with Globe
Angle or Corner configurations and
many trim sizes and materials
Valves may be furnished without
positioner for ON-OFF applications
Call for more information on our
plastic control valves
Write in 9 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1545
of hydrocarbon mixtures into pure components
However researchers say an innovative solution may
have come in the form of a novel chemical sponge This
porous material a metal-organic framework was devel-
oped by the same team at Nottingham just two years ago
Now in research published in Nature Chemistry for the
first time scientists have proven that it can be used toseparate hydrocarbon mixtures without the need for high
process pressures or very low process temperatures
Reusable MaterialsMade from cheap organic materials aluminum nitrate
salt and water the porous material called NOTT-300 is
able to adsorb different gases found in mixtures of hydro-
carbons at different rates making it possible to sepa-
rate them and extract the most useful ones NOTT-300
requires less energy to function than existing methods
as it operates at ambient temperatures and normal pres-
sures researchers say The gases that are adsorbed intoNOTT-300 can be removed without a significant energy
input and therefore the material can be easily reused
The team of scientists from Nottingham used Diamond
the UKrsquos synchrotron science facility as well as STFCrsquos
ISIS Neutron Facility and Oak Ridge National Laboratory
the UKrsquos and USArsquos world-leading neutron facilities re-
spectively to prove that the sponge works under real-life
conditions
Professor Martin Schroumlder Dean of the Faculty of Sci-
ence at Nottingham said in the news release ldquoIt is a very
important to be able to separate different hydrocarbons ef-
fectively and efficiently with low-energy consumption Po-rous solids such as the metal-organic framework system
studied here represent important materials for the future
development of low-energy separation technologies We
are most grateful to our collaborators at ISIS Neutron Fa-
cility Oak Ridge National Laboratory and Diamond Light
Source in bringing this work to fruitionrdquo
Significant Impact on Oil IndustryDr Sihai Yang the winner of Diamond Young Scientist
and BTM Willis Prize is a Senior Research Fellow at
Nottingham He led the project together with Professor
Martin Schroumlder Yang said ldquoWith the help of advancedcentral facilities like Diamond ISIS and ORNL we have
developed a new separation technique which can poten-
tially reduce the energy usage associated with oil petro-
leum and chemical industries which require the separa-
tion of raw hydrocarbons from crude oil
The discovery of the new material NOTT-300 could
have a significant impact on the oil industry by removing
the necessity for some energy-intensive refinement pro-
cesses researchers say
The research was funded by Engineering and Physical
Sciences Research Council (EPSRC) the European Re-
search Council (ERC) The University of Nottingham andLeverhulme Trust
12 | January 2015
Flow Control Magazine
Write in 21 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
No media contact - No risk of leaks
No process Shut-Downs for installation
No bypass needed
For hazardous area locations (FM approved)
Monitor your Total Acid Consumption
Increase your Plant Up-Time
Balance your Processes
PIOXreg S
PIOXreg S - the evolution of flow and concen-
tration measurement in acid production
Non-intrusive mass flow concen-
tration and density measurement
of aggressive media
wwwpiox-scom
wwwfleximcom
Contact us for a free trial measurement
Thank you for your votes and
making PIOXreg S a Flow Control
Awards Winner
THE OUTLOOK | News amp Notes
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1645
The ASCO trademark is registered in the US and other countries The Emerson logo is a trademark and service mark of Emerson Electric Co copy 2014 ASCO Valve Inc
1-800-972-ASCO (2726) | e-mail info-valveascocom | wwwascovalvecomSpoolValve
Now get spool valves with industry-leading ASCO solenoid technology built in
Delivering unmatched performance and durability our compact new valves are
perfect fits for all your onshore near-shore or offshore upstream control panels A
range of easily configured features and options includes superior temperature and
pressure ratings plus low-power models The industryrsquos toughest testing ensures
every rugged stainless steel valve meets or exceeds specifications Plus we design
and support every spool valve we make Ask for ASCO the ultra-reliable choice for oil
and gas control panels
These new spool valves will fit right in
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 174514 | January 2015 Flow Control Magazine
PPLICATIONS CORNER | Process Instrumentation
This is the final article in a series based on the troubleshoot-
ing of a mysterious unit shutdown due to flowmeter perfor-
mance problems
If yoursquove followed this column for most of 2014 you know
that what should have been a liquid ammonia stream to the
feed plant became problematic due to the occurrence of
bubbles of ammonia gas These bubbles caused an ultrasonic
flowmeter in a unit to indicate zero flow and caused the reactor
to scram (shut down) under warm operating conditions The source of the bubbles was traced back to the pres-
sure drop associated with a control valve located at the
exit of the liquid ammonia tank farm
This issue was resolved by identifying the problem
and fixing it at its source This was a pragmatic ap-
proach at the time (early 1980s) given the operation
of the cooling system in the unit and the limited selec-
tion of applicable flowmeter technologies
By the early 1990s changes were implemented that elim-
inated all process cooling requirementsmdashexcept for the small
jacketed cooler upstream of the liquid ammonia flowmeter In
other words after these changes the entire cooling system
would be operated and maintained to cool a few meters of
one small ammonia pipe Coincidently at about the same
time Coriolis mass flowmeters became more mature and
could reasonably measure the mass flow of liquid streams
with homogeneous low levels of vapor
The convergence of these two events resulted in another
approach to the problem that was not available in the early
1980smdashie install a Coriolis flowmeter that could operate in
the presence of bubbles The purchase and installation of a
Coriolis mass flowmeter was given high priority given its im-pact on unit operation economics and safety (by eliminating
the ldquomidget-makerrdquo (see March 2014 page 14))
Plant requirements and the technology that can meet
plant needs keep changing An excellent solution today can
become outdated in just a few years However there are few
substitutes for understanding fundamentals when addressing
a problem In other words there can be more than one way
to skin a cat FC
wwwspitzerandboyescom
Problem Solved AgainA Coriolis mass flowmeter provides a better solution
F o r B e t t e r P i p i ng S y s t e m P e r f o r m a nc e hellipFor Better Piping System Performancehellip
I d e a l f o r Ag g r e s s i v e C h e m i c a l s
1384 POMPTON AVENUE CEDAR GROVE NEW JERSEY 07009
973-256-3000 bull Fax 973-256-4745www p l as t om a t ic co m bull i n f o p la s t om a t ic co m
bull Rugged thermoplasticshandle corrosive andultra-pure chemicaltreatments
bull Constant pressure enhances
pump performancebull Prevents overpressure in
piping system
bull Wide range of pressuresettings
bull PTFE shaft and diaphragm designs
bull 1 4rdquo - 3rdquo sizes in PVC CPVC PVDFPolypro and PTFE
bull First State approved
thermoplastic valve for
anti-siphon applications
Write in 10 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
David W Spitzer
Ammonia Gas | Coriolis Flowmeter | David W Spitzer | Scram | Troubleshooting
FLOWSTREAM Find related content flowcontrolnetworkcom
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and Boyes
LLC offering engineering seminars strategic marketingconsulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer can be reached at 845 623-
1830 or at wwwspitzerandboyescom
The purchase and installation of a
Coriolis mass flowmeter was given
high priority given its impact on unit
operation economics and safetyldquordquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1845
Smart Valve Positioner
Beyond Control The NEW Research Controlreg SRD positioner does
everything you expect any valve positioner to do
plus more The SRDrsquos comprehensive diagnostics tool
continuously monitors for fugitive emissions delivers
real-time performance statistics and facilitates both
proactive and reactive process management Available
with integrated network communications the SRD is
compatible with Research Control valves and most other
pneumatically-actuated valves
Visit wwwbadgermetercomSmart-Valve-Positioners or
call 877-243-1010 for more information today
copy 2015 Badger Meter Inc
RESEARCH CONTROL is a registered trademark of Badger Meter Inc
Write in 11 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1945
Process improvements to increase yield or cut manufactur-
ing costs typically require enhanced process control but the
installed base of measurement instrumentation in a process
plant may simply be unable to facilitate improvements because
of age inadequate performance or unreliability Maintenance
cost and unscheduled process downtime for an aging process
plant can be very damaging to the balance sheet Upgrading
to new more accurate and more reliable instrumentation can
be prohibitively expensive New plant construction must alsomaintain a focus on optimizing costs for the process control
infrastructure The budget approval decision for new plant
construction must weigh such costs against projected market
conditions for the products that the plant is intended to manu-facture In todayrsquos volatile global marketplace return on invest-
ment calculations for plant upgrade or new plant construction
projects may go through several iterations before the trigger is
finally pulled or indeed not pulled
This article describes advances in two-wire instrumenta-
tion specifically in relation to flowmeters that have taken
place in the past few years and the significant cost benefits
that this new technology can realize for plant builders and op-
erators in terms of capital investment and cost of ownership
The Significance of Two-Wire Loop Power
A survey involving 204 participants in the chemical indus-try across Germany Switzerland the UK Canada and the
United States (Manfred Koenig PhD KIM Ludwigshafen
Germany 2006) revealed an 87 percent preference for two-
wire instrumentation versus four-wire in process applications
and 89 percent for utilities This overwhelming preference
may stem from the fact that older process plants were built
with two-wire twisted-pair cable networks connecting all
process units and measuring instruments together in an
overall plant control scheme
However these existing cables are relatively unsophisti-
cated and incapable of supporting anything but low-energy
instrumentation that is insensitive to interference from otherelectrical sources that might be sharing the same cable con-
duit Further the low energy levels supported by these two-
wire loops are more easily rendered safe in terms of explo-
sive risk in hazardous areas containing flammable materials
Many older process plants are also likely to have a significant
installed base of flowmeters employing pre-war (pre-1945)
technology such as positive displacement (PD) turbine vari-
able area (VA or Rotameter) and differential pressure (dP)
Market data firm Flow Research Inc (wwwflowresearch
com) indicates collectively a future compound negative annual
growth rate approaching minus 3 percent to 5 percent for PD
turbine and VA flowmeter types while dP is expected to keeppace with market growth (World Market for Flowmeters 2010)
YSTEMS DESIGN | Flow Measurement
16 | January 2015
Flow Control Magazine
The Two-Wire
ADVANTAGENew wiring options enable modern instrumentsto drive cost savings in existing plant systems
By Steve Milford
Advances in two-wire instrumentation have enabled mod- ern technology to be employed to the advantage of older
plant and process systems
Some chemical manufacturing plants are
competing for survival not only externally
against other global companies but also
internally among the global facilities of theirown company Other industry sectors face
similar challenges
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2045wwwflowcontrolnetworkcom January 2015 | 17
The Need to Replace Older TechnologiesUntil the 21st century two-wire loops were only able
to support these relatively unsophisticated instruments
which convert their measurement by various means into a
4-20mA output or pulse signal to the control system The
more advanced post-war flowmeter technologies such as
Coriolis ultrasonic or electromagnetic flowmeters have
until just eight years ago required a dedicated power sup-
ply for their function in addition to the output loop and
thus a four-wire infrastructure was required as a minimum
Therefore upgrading older two-wire meter devices to moremodern four-wire technology could require significant
expenditure in terms of the installation of separate power
cables and supply modules
There was a major breakthrough in 2006 when a true
two-wire loop-powered inline liquid ultrasonic flowmeter
was introduced (Figure 1) The nature of this breakthrough
was innovation in device power management This was the
missing piece up to that point because to be a true loop-
powered device the meter had to directly provide a full 16
mA span using less than 36 mA of remaining loop current
and less than 1 Watt of electrical energy The flowmeter
operated on a single 4-20 mA HART two-wire loop wasremotely powered by a DC supply was certified Class 1 Divi-
sion 1 and could be deployed as Intrinsically Safe through
the use of an approved safety barrier
A true two-wire loop-powered Coriolis flowmeter followed
in 2011 (Figure 2) employing a new and more advanced
common electronics platform A two-wire loop-powered inline
ultrasonic flowmeter for low-pressure gas was introduced in
2012 and a second two-wire loop-powered Coriolis meter fol-
lowed in 2013 offering improved measurement performance
and an additional high-performance meter tube material
Electromagnetic and vortex flowmeters had already been
available for some years in two-wire loop-powered form butimproved performance resulted as these designs were incor-
COURTESYENDRESS+HAUSER
Figure 1 A two-wire ultrasonic flow- meter released in 2006 operated ona single 4-20 mA two-wire loop
Write in 12 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
omegacom
reg
I I I I LL I
I I I I LL I
copy COPYRIGHT 2015 OMEGA ENGINEERING INC ALL RIGHTS RESERVED
1-888-826-6342
Prices listed are those in effect at the time of publication and are subject to change without noticePlease contact OMEGArsquos sales department for current prices
FPD3000 SeriesStarts at$630
FPD3300 SeriesStarts at
$790
Visit omegacomfpd3000
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OSXL-TIM3$999
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Positive Displacement Flow Meterfor Fuels and Oils
bull Aluminum Bodybull FKM Sealsbull Temperatures up to
80ordmC (176ordmF)bull NPT or BSP Threadsbull DIN JIS or ANSI
Connection (Availableon 1 and Larger Sizes)
Positive DisplacementFlow Meter for Solvents
Thermal Imaging CameraFor Inspection andFactory Diagnosis
Note Not for ExportUSA Only
Your One-StopSource for Process
Measurement and Control
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 214518 | January 2015
Flow Control Magazine
porated into their new common electron-
ics platform in 2013 So all the ldquomodernrdquo
flow measurement technologies mdash that
is to say those introduced post-war mdash
have become available as two-wire loop-
powered devices with one exception
namely thermal mass (thermal disper-
sion) meters Unfortunately the power
requirements for this technology exceed
what is currently deemed possible withtwo-wire loop-power management
Payback forTechnology UpgradeConsider a 1rdquo process line
containing a liquid process
ingredient costing $1lb at a
mass flowrate of 150 lbmin-
ute We have $150minute
flowing in the line translating
to $9000hour and $72000
per eight-hour shift That cal-culates further to $360000
per five-day working week and
for a working year of 40 weeks for
example that is $144 million Assume
the existing device is a turbine flowmeter
Now imagine a two-wire loop-
powered Coriolis mass flowmeter is
installed in place of the existing meter
The line would need to be drained and
probably one process flange replaced
allowing the Coriolis to fit mechanically
in place of the turbine However thetwo-wire loop already used for carrying
the existing meterrsquos flow signal to the
control room can be used unaltered
for the complete electrical installation
aspects of the Coriolis flowmeter
The upside of the change is signifi-
cant and clear cut Assuming the exist-
ing meter measurement uncertainty was02 percent of reading then measure-
ment uncertainty improves through use
of Coriolis to 01 percent of reading
giving a 01100 x $14400000 im-
provement in control of the ingredient
annually or $14400 A two-wire Coriolis
mass flowmeter with 01 percent mass
flow accuracy would be paid for in ap-
proximately 6-8 months In practice the
improvement in measurement uncer-
tainty would be greater as the operator
would gain temperature and density in-formation from the Coriolis and the mea-
surement would be devoid of any fluid
property dependence Viscosity change
for example can have a major impact on
turbine meter performance Mechanical
wear and tear that turbine meters even-
tually experience which causes them to
under-register flow is precluded by mod-
ern devices like Coriolis
Furthermore if the process ingredient
was being blended with another then ad-
ditional process improvements could berealized through in-line blending control
using Coriolis technology for final density
as the control point It is possible to have
dual 4-20 mA outputs from two-wire
loop-powered meters but as the main
4-20 mA output representing the prima-
ry variable is also HART then an external
HART Loop Converter or HART IO card in
the control system can provide second-
ary tertiary and quaternary variables as
4-20 mA signals A Coriolis meter is trulya multi-variable device Certain two-wire
devices are also available with Profibus
or Foundation Fieldbus communication
Cutting Wiring CostsIn 2003 WIBEXERA (International
Instrument Usersrsquo Associations) Report
T 2732 X 03 was published and it pro- vided an average survey of prices quoted
in projects at that time for the provision
of power supplies for four-wire instru-
ments The price ranged from euro1200
to euro1800 per instrument depending
upon design and plant characteristics
for an average cost of euro1500 (about
$2000) It would be reasonable to
assume an inflationary factor of 2 per-
cent per annum giving an approximate
current-day figure of $2500
From another source within thechemical industry an estimation of
$40foot to $50foot was given for in-
stallation of four-wire cabling For a
linear 50-foot cable run with for ex-
ample a 10-foot vertical at each end
this equates to $3150 Actual costs
and budget estimates have been given
as high as $10000
The Extent of the Opportunity The modern post-war flow measure-
ment technologies have different powerrequirements and consequently they
are not all available for the
same size range in two-wire
loop-power form For example
two-wire Coriolis flowmeters
are limited to 2rdquo diameter
electromagnetic and inline
low-pressure gas ultrasonics
are limited to 8rdquo and vortex
and inline liquid ultrasonic are
limited to 12rdquo
Nevertheless for thechemical industry in particu-
lar perhaps two-thirds of the
process pipes in a plant will be no larger
than 2rdquo and even when the host process
pipe is larger a correctly sized flowmeter
can still be less than 2rdquo There is consid-
erable scope for two-wire loop-power to
deliver value for flow measurement ap-
plications with total safety
The virtues of Coriolis technology
have been covered but what about
other two-wire technologies An elec-tromagnetic flowmeter in two-wire form
YSTEMS DESIGN | Flow Measurement
In todayrsquos volatile global mar-
ketplace return on investment
calculations for plant upgrade or
new plant construction projects
may go through several itera-
tions before the trigger is finally
pulled or indeed not pulled
ldquo
rdquo
COURTESYENDRESS+HAUSER
Figure 2 Two-wire Coriolis flowme- ters became available in 2011
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2245
can be used on water wastewater or
a light water-based slurry provided the
fluid has around a 20 microSeimenscenti-
metre (microScm) electrical conductivity
A magnetic flowmeter is full bore un-
less flowrates dictate a reduced meter
size in the interests of performance and
so there are no intrusions into the flow
stream and no pressure loss An accu-
racy of 05 percent of reading is normal
from a two-wire magnetic meter and a
modest five diameters (5D) of straight in-let run is needed to avoid error from up-
stream flow disturbances When the fluid
exhibits insufficient conductivity then
the same performance and installation
requirements can be met by an inline ul-
trasonic flowmeter provided the liquid is
essentially clean and bubble-free
For gas or steam applications a vor-
tex meter is the normal choice Using a
built-in temperature sensor a two-wire
loop-powered vortex meter can calculate
mass flow of saturated steam using in-ternal steam tables An external pressure
input allows mass flow of steam to be ac-
curately calculated even when saturated
steam becomes superheated as can oc-
cur downstream of a pressure regulating
valve With mass flow known the vortex
meter can calculate energy and heat flow
A new and exciting development is
the ability of the vortex meter to indicate
wet steam and calculate dryness frac-
tion or steam quality For safety and ef-
ficiency saturated steam should be dry
and free from condensate that is to say
it should possess a high steam quality
factor However the dry or wet state of
saturated steam can sit on a knife-edge
and shift to the opposing state due to
the slightest change in process condi-
tions Rapid and reliable indication of
this change of state is now available
Perhaps the most astonishingachievement in the power management
of two-wire loop-power flowmeters is
that of the ultrasonic biogas meter It is
now possible not only to measure the
flow of wet dirty variable composition
and low-pressure anaerobic digester
gas landfill gas and coal bed methane
gas with a two-wire loop-powered ultra-
sonic flowmeter but also the same de-
vice uses an inbuilt temperature sensor
in combination with measured sound
velocity to calculate methane contentcalorific value and energy flow
Technology to Take UsForwardModern flow technologies provide instru-
ment engineers with vital self-monitoring
information The format of such infor-
mation is easier to understand and act
upon when presented in accordance
with harmonized international guidelines
for online plant asset management eg
NAMUR Standard 107
Continuous plain-text self-diagnostic
and process-related information with
suggested remedies (Figure 3) make it
possible for instrument engineers andoperators to take action at the appro-
priate time mdash immediately or during
the next scheduled shutdown mdash saving
time and money by knowing the exact
health of their measuring point and the
probable actions required to rectify any
abnormal conditions Device verifica-
tion offering third-party validated trace-
ability can be performed on demand ei-
ther locally or remotely from the control
room without the expense of a man in
the field Calibration is then avoided ordeferred without process interruption
Where a process plant has a large
installed base of older mechanical tech-
nologies the decision to embark upon a
program of replacement for plant mod-
ernization cannot of course be taken
easily There are the stocks of spare
parts to consider along with the plant
instrument technicians who are trained
on and at ease with the old devices
However a process plant that retains
the older technology going forward willbe at risk and may find it increasingly
difficult or even impossible to maintain
a cost position that competes effective-
ly in the global market FC
wwwusendresscom
wwwflowcontrolnetworkcom January 2015 | 19
Steve Milford
is a Flow Product
Business Manager
for Endress+Hauser
Inc in Greenwood
Ind He has been
involved in flow
measurement since
1983 and has been
actively involved with standards devel-
opment for flow technology within the
International Standards Organization
(ISO) and the British Standards
Institute Mr Milford can be reached
at stevemilfordusendresscom
Steve Milford
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Coriolis Flowmeter | Magnetic Flowmeter | Two-Wire | Ultrasonic Flowmeter | Vortex Flowmeter
Figure 3 A modern instrumentrsquos display module can provide continuous plain- text self-diagnostic and process-related information
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2345
The bottom line is the volume of gas under one set of
pressure and temperature conditions is not the same as it
would be for the gas under different conditions Why is thisimportant Without compensation for compressibility read-
ings taken by gas flowmeters can result in measurementsmdash
and costs to the buyermdashsignificantly lower or higher than they
should be
The flow of gas in a system can be accounted for and
reported in a number of ways such as by volume by mass
flowrate and by energy Inline turbine meters can offer both
reliability and accuracy in measuring gas flow when matched
with a monitor capable of calculating and displaying results
that have been adjusted for the nature of the gas and impor-
tantly the pressure and temperature
Measuring Flow with an Inline TurbineFlowmeter
With an inline turbine meter gas flows into the meter through
a length of piping that helps to pre-condition the flow by
reducing undesirable swirls and asymmetry Where consid-
ered necessary a flow straightener may even be installed in
line to create a uniform flow profile to the extent possible
As can be seen in Figure 1 a rotor support within the tur-
bine housing further conditions the flow and directs it through
the blades of the rotor High-precision ball bearings allow the
rotor to freely rotate on the shaft
The rotorrsquos rotational speed is directly proportional to the velocity of the fluid passing through the meter The rotor itself
incorporates magnets (or magnetic blades depending on thedesign) while the housing is non-magnetic
A proximity sensor (also known as a pickup coil) is located
in line with the rotor and detects the electrical pulses gener-
ated by the ferrous rotor spinning through the magnetic field
Each pulse represents a discrete volume of gas The out-
put frequency provides the indication of the gas flow rate and
the accumulated pulses over a specified time represent the
total volume of fluid for that measurement period
Need for Calibration The flowrate of the gas through the meter cannot be deter-
mined accurately unless the meter is calibrated The fac-tory calibration determines the meterrsquos constant known
as a K-factor which is then inputted into the gas monitor
PPLICATION NOTES | Flow Measurement
20 | January 2015
Flow Control Magazine
COMPENSATING for
Compressibility inMeasuring Gas Flow Why K-factor adjustment is essential foraccurate inline turbine flow measurement
Unlike crude oil and other liquid fossilfuels natural gas poses a challenge
in monitoring the quantity of gas flowing
through pipelines While liquids do not com-
press gases do and the mass flowrate of
gas being transmitted through gathering
lines depends on both the pressure and
temperature
By Kevin Clark
Figure 1 Internal components of a liquid turbine flowmeter
C O U R T E S Y
T U R B I N E S
I N C
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2445
Wondering Whether the
Pump Guy Seminar
Is for YouCheck out the ldquoPump Guy Insightsrdquo
video series flwctrlcompginsights
PUMP GUY INSIGHT 1NPSHa vs NPSHrmdashWhy all pumps need gauges
PUMP GUY INSIGHT 3How to Operate Your Pump at Best Efficiency
PUMP GUY INSIGHT 5Head vs Flow
PUMP GUY INSIGHT 2 Your Pumps Are Constantly Moving On Their Curves
PUMP GUY INSIGHT 4 The Role of the Pump Reliability Chain
PUMP GUY INSIGHT 6How to Read a Pump Curve
PARTNER SPONSORSFor more information and to register
for upcoming Pump Guy Seminars
visit FlowControlNetworkcomPumpGuy
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2545
PPLICATION NOTES | Flow Measurement
22 | January 2015
Flow Control Magazine
Gas flowmeters measure the actual volume of gas passing
through the meter per minute irrespective of pressure and
temperature1
The volumetric flowrate of a gas is often corrected to
ldquostandardizedrdquo conditions of pressure and temperature While
ldquostandardrdquo conditions can vary depending on the definition
in the US this typically means a pressure of 1473 PSIA(pounds per square inch absolute) and a temperature of 60 F
The flowrate measurement is reported in standard cubic feet
per minute (SCFM)
Compensating for changes in pressure and temperature is
critical Consider a meter system setup for flowing conditions
of 60 PSIG (pounds per square inch gauge) and 60 F and the
line pressure decreases to 50 PSIG while the temperature
remains constant The difference in SCFM between the two
is more than 15 percent which would cost the buyer more
for the gas than it should As Table 1 demonstrates even a
small variation in pressure will result in a surprisingly high er-
ror percentage
Automation of the K-Factor The K-factor is established by an initial factory calibration In
the case of a non-compensated flow monitor any variations
in pressure and temperature will result in manual adjust-
ments needed to the K-factor In order to maintain accurate
flow measurement users must monitor pressure and temper-
ature and make corresponding adjustments to the K-factor To eliminate these manual adjustments some suppliers offer
a flow monitor that automatically adjusts for any changes in
pressure and temperature
These monitors provide accurate flow measurement regard-
less of changing environmental conditions in some cases sup-
porting applications with pressures as high as 15000 PSIG and
temperatures between -350 F to 350 F with a standard accura-
cy of +-1 percent over a flow range of 05 ACFM to 650 ACFM
Final NotesDuring the operation of a flowmeter system the ability to obtain
a readout mdash and to adjust for line pressure and temperaturechanges mdash is sometimes compromised by a lack of electric
power This issue is especially true along gas pipelines in remote
areas To overcome this limitation some manufacturers have
designed low-powered flow monitors which can operate for up
to on year on a single lithium D-cell battery
It is important for users to recognize the effects of the
compressibility of gas As such the quantity of a gas flow-
ing through a gas flowmeter depends on the pressure and
temperature In order to ensure accuracy any flowmetering
system must employ a means to correct for these effects
Otherwise the readout is certain to be in error and could be
unnecessarily costing money This is particularly crucial onwellhead production and in billing scenarios FC
wwwturbinesincorporatedcom
Notations1 The measurement factor in the US is known as the
ACFM actual cubic feet per minute (Metric units are typically
ACMH actual cubic meters per hour)
Table 1 Error induced by line pressure changes
Constant Temperature with Varying Pressure
Pressure Temperature PulsesSCF Error
50 60 2556027821 1546
51 60 2517123288 1370
52 60 2479385307 1199
53 60 2442762186 1034
54 60 240720524 873
55 60 237266858 717
56 60 2339108911 566
57 60 2306485356 418
58 60 2274759285 275
59 60 2243894166 136
60 60 2213855422 000
61 60 2184610304 132
62 60 2156127771 261
63 60 2128378378 386
64 60 210133418 508
65 60 2074968632 627
66 60 2049256506 743
67 60 2024173807 857
68 60 1999697703 967
69 60 1975806452 1075
70 60 1952479339 1181 Flow Measurement | K-Factor | Measurement
Accuracy | Turbine Flowmeter
Find related content flowcontrolnetworkcomhellipSearch on
FLOWSTREAM
Kevin Clark is senior develop-
ment engineer for Turbines Research
amp Development LLC Turbine RampD is a
subsidiary and the research and techni-
cal support arm of Turbines Inc which
serves a range of industries and applica-
tions from oil amp gas to cryogenic liquids
to custody transferKevin Clark
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2645
Pumps Bearings amp Seals TECHNOLOGY REPORT
FEATURES
SYSTEMS DESIGN
The ComplicatedCase of
Compressors
withSide-Streams
24 28 32BEST PRACTICES
How PumpingSystems
AffectSealing
Performance
TECH OUTLOOK
BearingSuppliers
Drive Gains InDeveloping
Markets
wwwflowcontrolnetworkcom January 2015 | 23
S P E C I AL S E C T I O N
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2745
The design and operation of compressors with side-
streams has always been difficult because flow entering the
compressor needs to be mixed with the core flow already
in the compressor (compressed in section-1) in a manner
that does not degrade the aerodynamic performance of sur-
rounding sections Minimizing losses and ensuring proper
mixing of the side-stream flow and core-flow are required to
ensure effective performance of a compressor of this sort
Key considerations for an application involving compres-
sors with side-stream flow include
The plant process typically dictates the side-stream
flange pressure
The impellers upstream of the side-stream should
achieve the necessary pressure for the core-flow
The side-stream flow is typically at a temperature dif-
ferent from compressor core-flow temperature
Process plants need some degree of operational flex-
ibility ie the ability to support variations in core-flow condi-
tions and side-stream conditions
Modern process plants are usually specifying more than
one operating conditions (sometimes two or more manda-
tory conditions) which can present challenges to compres-
sors with side-streams Adding to these issues modern
compressors should operate with much higher impeller tip
The COMPLICATED CASE ofCompressors with Side-StreamsConsidering key system design requirements
to ensure operational efficiency By Amin Almasi
4 January 2015
Flow Control Magazine
|
y
g
Some compressors in certain applications
have one or more incoming side-streams
(or side-loads) that introduce side-stream
flow to mix with the core flow In other words
a radial side-stream inlet is utilized in multi-
impeller centrifugal compressors to introduce
additional gas into the mid-stage of a com-
pressor This design enables optimization in
some process plants However the flow dis-
tribution after the junction of the side-stream
and the main return channel of the upstream
section can significantly affect the perfor-mance of the next section of compressor
In most cases the pressure levels at these
side-streams should be accurately predicted
to meet the theoretical performance
Compressor station at a natural gas processing plant
R U D M E R Z W E R V E R I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2845
speeds and inlet Mach numbers compared to previous
generations of compressor technology
Likewise side-streams are now com-
monly used with medium-sized and
large-sized compressors (eg 1ndash60
MW) The costs associated with cor-
rections on side-stream compres-
sor applicationsmdashany repair
inefficient operation and power
lossesmdashwould be very high Fur-
ther compressors with side-streams
are usually sensitive and difficult
machines to operate In particular
performance curves (performance
pressures efficiency etc) are sen-
sitive to suction inlet conditionsside-stream inlet conditions vol-
ume flow ratio (side-stream vol-
ume to core-flow volume) and side-stream losses
Compressors with side-stream often perform far below
expectations The main reason is that side-stream compres-
sors are different than conventional compressors (without
a side-stream) in design and operation For a compressor
with side-streams tighter tolerances in operating conditions
must be identified and applied Uncontrolled variations of
suction pressure or side-stream pressure are major prob-
lems Another major issue is the variations of the flow ratio
(side-stream flow to core-flow)
Compressor Side-Stream amp Mixing SectionIn many centrifugal compressors the portion of the side-
stream system from the flange connection to the mixing
section is similar to a compressor inlet A great challenge
is ensuring the mixing section provides circumferentially
uniform merged-flow with minimum losses This can be
achieved via effective design of the inlet configuration and
mixing section of the side-stream compressor such that
the impeller can be maintained over the whole operating
range of the compressor In many cases while there are
mixing sections provided for the machine the flows do not
completely mix before entering the impeller of the section-2
(the impeller after the mixing section) Non-uniformity at
inlet flow to the impeller is a key concern for compressor
performance
Another consideration is a compact design of the side-
stream mixing section Specifically a mixing section with
less axial length is always preferred This axial length can af-
fect the compressor rotor dynam-
ics the rotor length and over-
all compressor performance
(design cost operation and
reliability)
The side-stream exit pressure
(side-stream pressure at inlet
of the mixing section) is mainly
a function of the side-stream
flow velocity and the pres-
sure in the previous section of
the compressor Conversely the side-
stream flange pressure can depend on
side-stream flow velocity and section-1
exit conditions Therefore the side-stream
inlet flange volume flow is a function of theflange pressure compressibility (at that
pressure and temperature) and mass flow
Some engineers assume that the side-stream flange pres-
sure is equal to the inlet pressure of the first impeller of the
section-2 This is not true The mixed total pressure can be
estimated on a mass-averaged basis using side-stream total
pressure and return channel exit (section-1) total pressure
In some designs because of the lower static pressure at
the side-stream exit the total pressure at the return channel
exit is lower even though the velocity upstream is roughly
matched for both streams The pressure usually increased
at the returned channel but it can be reduced again at the
side-stream exit While simple in nature this can have an
impact on the prediction of pressure at the side-stream exit
and overall mixing section performance Based on basic flow
principles it was usually assumed that the static pressure
was equal between both flow streams at the mixing location
While this assumption might be used in rough calculations
the accurate simulations have shown this assumption is not
true In fact there are some points (for instance the shroud
wall at the exit of the return channel and the hub wall at
the exit of the side-stream) where this assumption is true
However this is not valid for all locations There are pressure
changes that occur from a side-stream flange to the inlet
of the next section (section-2) which depend on different
factors The first factor is the frictional losses due to side-
stream geometry from side-stream flange to plenum mix-
ing section etc The other factors are pressure changes due
to local curvature and geometry details of mixing section
Another consideration is the operation of a compressor
with side-stream at part-load The performance of the side-
wwwflowcontrolnetworkcom January 2015 25
Figure 1 An example of a centrifugalcompressor with side-stream
COURTESY SIEMENS
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 29456 January 2015
Flow Control Magazine
|
y
g
stream path the mixing section and
the downstream impellers when ma-
chine is operated at part-load or even
off-design operating flows will result
in additional compressor performance
problems In such a case both veloc-
ity profiles and pressure variations in
various parts (side-stream path mixing
section etc) will be different resulting
in complicated flow patterns and com-
plex aerodynamics behaviors
Side-Stream CompressorSectional Performance
Typically vendor-supplied compressor
performance curves reflect flange-to-flange performance because that is
what the plant engineers need to
evaluate the proper operation of their
system (for example from suction to
side-stream and from side-stream to
discharge) In many cases compres-
sor vendors also provide the over-
all compressor performance curves
and performance curves for section-1
(from suction to side-stream) and sec-
tion-2 (from side-stream to discharge)
Flange-to-flange data if not interpret-
ed properly can lead to false conclu-
sions about the relative performance
of individual sections of a compression
system For example if side-stream
losses from the flange to mixing sec-
tion are attributed to the downstream
section (section-2) it will cause the
downstream section (section-2) to
appear low in performance while the
upstream section (section-1) will show
high performance levels
An important behavior to con-
sider is when the actual side-stream
pressure is different than the rated
side-stream pressure When the side-
stream pressure is slightly higher than
the outlet pressure of the section-1
it (section-1) shows a relatively higher
performance compared to the real sec-
tion-1 performance In some cases
the performance of section-1 could be
considerably higher than section-2 In
other words when performance is de-
termined flange to flange the higher
flange pressure is seen as extra ldquopseu-
dordquo work done by the section (since this
is an inconsistent thermodynamic vol-
ume) resulting in a relatively high sec-
tional efficiency (section-1 shows a rel-
atively high efficiency) This is the case
for many compressors with side-stream
because the whole system is designed
(or specifically the side-stream location
is selected) in a way aimed at main-
taining the real side-stream pressure(side-stream inlet) above the section-1
outlet pressure because if the real side-
stream pressure becomes lower than
the section-1 outlet pressure the flow
may (theoretically) reverse
This is particularly important when
the side-stream mass flow is much
lower than the mass flow of core-flow
The above-mentioned reasons explain
why in many simulations calcula-
tions and performance reports related
to compressors with side-stream the
section-1 shows a relatively good ef-
ficiency and section-2 appears low in
efficiency
When the side-stream pressure is
slightly lower than the outlet pressure
of the section-1 the section-1 might
show a relatively lower performance
compared to section-2 This could oc-
cur in some recycle services where the
side-stream is actually a recycle flow
with a mass flow around two to five
times the core-flow The side-stream
(recycle) flow is returned from down-
stream of the compressor to be slightly
compressed and recycled to the down-
stream Such a recycled side-stream
compressor can present unique chal-
lenges for design and operation This
kind of machine usually needs very
special operating procedures and very
fine adjustments regarding operating
pressures and flows
Side-Stream Compressor
Performance amp Operation An important consideration is the sen-
sitivity of compressor overall perfor-
mance curve and sectional perfor-
mance curves to the flow ratio (ratio
of side-stream flow to core-flow) and
to the inlet conditions Variations in
the flow and pressure of the main
suction and side-stream inlet should
be controlled within tight tolerances
For compressors with side-stream the ASME PTC-10 code stipulates limits on
flow ratio (side-stream volume to core-
flow volume) The acceptable variation
in volume flow ratio in a compressor
with a side-stream is +-5 percent as
per ASME PTC code The requested
side-stream pressure tolerance is not
usually specified in compressor codes
but it should be around +- 2 percent
(or sometimes +- 25 percent)
Variance in flow ratio impacts the
velocity levels where the two streams
merge Significant variation in the ve-
locity profile upstream of the impeller
changes the incidence on the blade
leading edge of the following impel-
ler This change in incidence leads to a
change in sectional performance over-
all compressor performance and train
efficiency
If the flow ratio is varied between 95
percent and 105 percent (tolerances
specified in the ASME PTC-10 code)
the flange pressure changes accord-
ingly resulting in a change in the sec-
tional performance and overall perfor-
mance The sectional efficiency varies
sometimes more than +- 4 percent
This variance reduces as the flow is de-
creased toward surge However as the
flow is increased toward overload the
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3045wwwflowcontrolnetworkcom January 2015 27
variance increases up to higher values
(even in some cases three to five times
compared to variations near the surge
zone) For example in a case study
for a compressor with side-streams a
+- 5 percent variation in flow ratio and
associated changes (pressures losses
etc) the sectional efficiency reduced by
approximately 34 percent at the rated
flow at allowable operating points at
the end of curve (near the overload
ie choke) efficiency reduced by ap-
proximately 55 percent These results
show that the variation in sectional
performance and overall performance
due to flow ratio is highest at operat-ing points near the overload and low-
est at operating points near the surge
For compressors which work most of
the time at high flow (flow higher than
rated flow and discharge pressure low-
er than rated pressure) the effects of
flow ratio deviations (and subsequently
efficiency reduction) would be higher
than compressors working on the left-
hand side of curve (say with sufficient
margins near the surge)
In the compressor codes (such as
API 617) the compressor power varia-
tions should be maintained below 4
percent However in some applica-
tions clients require tighter tolerances
on the consumed power sometimes
below 2 percent (or even below 15
percent) Some studies suggest while
+- 5 percent of volume flow ratio is
suitable for performance test as per
ASME PTC-10 code some plants re-
quire tighter control on the consumed
power and compressor performance
(lower limits on the efficiency) the tol-
erances on the volume flow ratio could
be tighter than ASME PTC code In this
regard +- 4 percent tolerance can be
suggested on the volume flow ratio (ra-
tio of side-stream flow to core-flow) of
compressors with side-streams
Based on operational experiences
acceptable variations in volume flow
ratio and inlet pressures (suction inlet
and side-stream inlet) of a compressor
with side-streams are +- 4 percent
and +- 2 percent respectively
Another important consideration is
the required adjustments for the flow
ratio (side-stream flow to core-flow)
Compressors with side-stream usually
require fixed side-stream flange pres-
sures For a compressor with some variations in operation conditions (even
small changes) it is not usually pos-
sible to achieve optimum operation by
keeping the flow ratio (side-stream to
core-flow) constant The flow ratio has
to be adjusted according to the inlet
flow at which the machine is operating
in order to get the required correspond-
ing side-stream flange pressure
Thermal changes have also been
known to cause some instability in
centrifugal compressors An example is
the thermal-induced change of resid-
ual unbalance For compressors with
side-streams which feature tempera-
ture differences between core-flow and
side-stream flow the thermal behav-
ior of the compressor is usually more
complex and requires more attention
Heavy Gas ChallengeHeavy gases (such as heavy hydrocar-
bon gases eg propane propylene
MTBE (Methyl Tertiary Butyl Ether))
have very low gas sonic velocities that
produce high Mach numbers in the
aerodynamic flow paths For these
services because of high Mach num-
ber high flow coefficient stages have
very narrow flow maps characterized
by limited surge and choke margins
Compressors with side-streams in
these services present great challeng-
es This is to say the side-streams and
associated mixing further complicate
design operation and performance
prediction because the pressure tem-
perature and flow conditions at each
one of these side-streams as well
as at the exit of the machine require
stringent tolerances to optimize the
overall efficiency and performance
As such it is important to accuratelymodel design operate and moni-
tor performance characteristics of any
impellers diffusers return channels
and generally all flow-path components
in a compressor with side-stream FC
Amin Almasi
is a senior rotating
machine consultant
in Australia He is
a chartered profes- sional engineer of
Engineers Australia
(MIEAust CPEng ndash
Mechanical) and
IMechE (CEng MIMechE) holds
bachelorrsquos and masterrsquos degrees
in Mechanical Engineering and is
a registered professional engineer
in Queensland He specializes in
rotating machines including cen-
trifugal screw and reciprocating
compressors gas turbines steamturbines engines pumps subsea
offshore rotating machines LNG
units condition monitoring and reli-
ability Mr Almasi is an active mem-
ber of Engineers Australia IMechE
ASME and SPE He can be reached
at aminalmasiymailcom
Amin Almasi
Compressor | Gas Flow | Performance Curve | Side-Stream Flow
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3145
The pressure in the stuffing box
containing the packing can be estimat-
ed by the following equation
SBP = [Discharge ndash Suction] 3 + Suction
Pressure at the bottom of the stuff-
ing box will be higher than the suction
pressure but considerably lower than
the discharge pressure It should be
noted this calculation will yield a con-
servative estimate of stuffing box pres-
sure that can be further reduced by
pump design
A hole in the stuffing box serves as
a port for injecting clean fluid that cir-
culates around a lantern ring aligned
under the flush port The fluid flushes
solids back into the process to protect
the packing from abrasive wear If the
clean fluid is injected at a pressure ex-
ceeding that at the bottom of the stuff-
ing box some of it will leak back into
the process and some will leak out to
the atmosphere Recommended flush
injection pressure is 15ndash30 PSI (1ndash2
Bar) greater than the pressure at the
bottom of the stuffing box
Fluid injection is also used to lubri-
cate and cool dry-running packing that
is subject to frictional heat and to pre-
vent air from entering the pump which
reduces flow and operating efficiency
Centrifugal pumps utilize three
types of impellersmdashopen semi-open
and closed (Figures 2 3 amp 4) Open
designs prevent fluids with large solids
from clogging the impellers but at theexpense of pump efficiency Backing
plates on semi-open designs serve to
trap the fluid for more efficient opera-
tion Closed impellers are for use with
clean fluids since solids could ac-
cumulate in the eye which would re-
quire tearing down the pump to remove
them
Single-Stage CentrifugalPumpsSingle-stage centrifugal pumps typi-
cally have good bearing support of the
shaft with few run-out or ldquowhiprdquo prob-
lems However in some cases they
are subject to cavitation This occurs
in the eye of the impeller where the
fluid is under vacuum If the pressure
is low enough it will cause the material
to vaporize forming air or water vapor
bubbles As the fluid passes through
How Pumping Systems Design Affects Sealing Performance
By Chris Boss
8 January 2015
Flow Control Magazine
|
Understanding how different types of pump designs impact
sealing is critical to optimizing efficiency safety and lon-
gevity of the sealing system Used for a wide variety of media
including clear fluids solutions and slurries single-stage
centrifugal pumps are one of the most common
types (Figure 1) Fluid drawn into these pumps
enters the eye of an impeller that spins itto the outside of its container
or volute building pressure as
it moves toward discharge
Some of this fluid will work
its way behind the impeller
where it must be sealed with
compression packing or a
mechanical seal
Figure 1
Figure 2 Figure 3 Figure 4
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3245
the pump under increasing pressure
these bubbles implode sending shock
and vibration through the impeller
adversely affecting the seal This phe-
nomenon can be mitigated by running
the pump at slower speed and higher
pressure at the suction end to prevent
air from entering the fluid
Double-Ended Split-CasePumpsOperating on the same centrifugal prin-
ciple but slightly different geometry are
double-ended split-case pumps (Figure
5) Fluid enters both ends of the pump
and is directed into the eye of an impel-ler which spins it out of the volute to
discharge Packing is installed on both
the shaft and bearing ends so the stuff-
ing box is exposed only to suction pres-
sure which is usually quite low
Axial Flow Pumps Axial flow pumps operate like hydro
turbines in reverse whereby a propeller
(or axial impeller) pushes the fluid to
discharge (Figure 6)
Since the stuffing box is located
downstream of the propeller at the dis-
charge end of the pump the packing is
exposed to the full discharge pressure
Vertical PumpsVertical turbine pumps are typically
flange-mounted on a floor extending
downward into a water-filled sump
hole (Figure 7) Available as single- or
multi-stage pumps they feature an
impeller or series of impellers rotated
simultaneously by a single shaft The
impellers increase the pressure of the
upward flow subjecting the stuffing box
to full discharge pressure
Vertical pumps can be quite long so
inadequate bearing support can cause
the shaft to run out This can induce
undesirable lateral motion on the pack-
ing Worse the packing may be forced
to serve both as a bearing and a seal To
withstand these conditions the packing
should be resilient elastic and resistant
to deformation These properties rule
out packing such as graphite foil in favor
of fiber-based materials
Multi-Stage PumpsMulti-stage pumps are used for high-
pressure applications such as feeding
the boilers in steam-powered generating
plants Stuffing box pressure can vary
with pump design and number of stag-
es Designed for clean fluids and high
operating speeds these pumps typically
have high- and low-pressure ends with ahydraulic pressure equalization line run-
ning between the stuffing boxes
Like vertical pumps multi-stage
pumps feature a series of impellers to
build fluid discharge pressure In the
case of the six-stage pump pictured in
Figure 8 fluid enters at the drive end
where a stuffing box is exposed to suc-
tion pressure Channeled from one
impeller to the next through the pump
casting the fluid can reach extremely
high pressures at discharge
A second stuffing box located at the
bearing end is exposed to an intermedi-
ate pressure from the third impeller This
pressure is greater than the suction pres-
sure but much less than the discharge
pressure which can reach 2000 PSI
Fortunately the stuffing boxes in
these pumps are not exposed to dis-
charge pressures and typically see be-
low 500 PSI which is within the range
of some packing materials
wwwflowcontrolnetworkcom January 2015 29
Figure 5
Figure 6
Figure 7
Figure 8
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 33450 January 2015
Flow Control Magazine
| Gear PumpsPositive-displacement or gear pumps
operate on a different principle than
centrifugal pumps In external gear
pumps the fluid flows around the out-
side of the gears the intermeshing
of which forces it through the pump
to discharge (Figure 9) This design
makes these pumps particularly suit-
able for use with highly viscous fluids
such as resins emulsions syrups and
adhesives As such they are used for
transfer or metering applications
It should be noted gear pumps will
continue to displace fluid as long as
their shafts are turning which can pose
a problem if a clog occurs at the dis-
charge The resulting buildup of pres-
sure can blow out seals and damage
the pump Therefore most gear pumps
have pressure relief valves to divert
fluid back to the suction side for re-
circulation through the pump Internal
gear pumps operate slightly differently
but also have pressure relief valves to
prevent damage from excessive pres-
sure (Figure 10) In both external and
internal gear pumps the maximum
stuffing box pressure is determined by
these valves
Other rotating equipment includes
mixersagitators which are similar to
pumps in terms of the speeds to which
the packing is exposed There are ba-
sically three types of mixersagitators
top- bottom- and side-entry Top-entry
models are subject to the same con-
cerns about shaft run-out ldquowhiprdquo and
lateral forces on the paddles that are
encountered in some vertical pumps
Although some fluid may splash onto
the packing these mixers basically run
dry so the packing must have the abil-
ity to dissipate the resulting frictional
heat
In bottom-entry mixers the packing
is always exposed to fluid and may also
be exposed to solids requiring abra-
sion-resistance If the seal fails the en-
tire contents of the tank will eventually
drain out onto the bearings the floor
and other components under the stuff-
ing box
The packing in side-entry mixers may
be fully or intermittently exposed to flu-
id as well as side loading and vibration
Aside from media temperature
speed and other application variables
the configurations and operating prin-
ciples of rotary-type pumps exert differ-
ent forces on the seals used to keep
them from leaking These forces can
spell the difference between accept-
able seal performance and failure
Understanding these differences has
important implications that should be
taken into account to assure proper
sealing selection for long-term trou-
ble-free performance FC
wwwgarlockcom
Chris Boss is
a senior applica-
tions engineer for
Garlock Sealing
Technologies in
Palmyra NY He
has held various
positions in produc-
tion engineering
product development and applica-
tions engineering for the companyrsquos
compression packing division He
is a BSME graduate of the State
University of New York at Buffalo Mr
Boss can be reached at 800 448-
6688 or chrisbossgarlockcom
Chris Boss
Cavitation | Centrifugal Pump | Pump Packing | Sealing System
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Figure 9
Figure 10
Aside from media temperature speed and
other application variables the configurations
and operating principles of rotary-type
pumps exert different forces on the seals used
to keep them from leaking These forces can
spell the difference between acceptable seal
performance and failure
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3445
NS IDERNDUSTRIAL AUTOMATION + PROCESS CONTROL
WANT
INFORMATION
ON THE
automationindustry
SUBSCRIBE NOW at wwwiainsidercouk
Published by Spitzer and Boyes LLC Write in 15 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3545
Frost says the push from developing
economies is important as the market
is technologically mature and seeing
restricted growth in developed econo-
mies This is particularly true in Europe
and North America where recent finan-
cial insta-
bility has
reduced capital expenditure across end-
user industries
Bill Moore senior vice president of
sales development and channel man-
agement for global bearings manufac-
turer SKF says ldquosmartrdquo products and
the expansion of robust reliability pro-
grams are helping to drive new invest-
ment particularly in developed coun-
tries where the cost to compete is
high Frost says the magnitude of
the existing global installed base will
strengthen the need for replacement
and upgrades adding to market de-
mand as well
Frost says despite the potential
in developing economies the focus
on price as a product differentiator
may lead to intense price pressures
among manufacturers and bring down
the value of the overall market in the
short term The growing trend among
consumers to choose low-cost Chinese
imports will complicate this challenge
As price and quality become stan-
dardized across the globe customers
will base more of their purchasing deci-
sions on value-added services accord-
ing to Frost This will push manufactur-
ers to create more maintenance-free
solutions such as lubrication-free
bearings that offer end-users savings
on service and replacement costs and
reduce downtimeldquoOffering a complete line of prod-
ucts with comprehensive services will
be another feather in the cap of ven-
dors looking to widen their consumer
baserdquo notes Frost Industrial Automa-
tion and Process Control Research
Analyst Guru Mahesh
Moore says the trend of outsourcing
manufacturing to regions where labor
and production costs are favorable is
becoming less of a factor
ldquoThe days when cheap labor made
a significant difference in where a prod-
uct is manufactured mdash particularly high
value-added products or high weight
and bulk products mdash are coming to
an end as the cost of transportation
storage and inventory balance out the
benefits of production costs where la-
bor is a smaller percentage of the cost
of manufacturingrdquo Moore says ldquoLocal
manufacturing development will indeed
come to developing countries as their
ability to create markets that generate
economies of scale that support local
production is a clear trend and one that
all manufacturers will pay attention tordquo
Moore says that development of
maintenance-free or predictive tech-
nologies and products will be a sig-
nificant advantage to everyone in the
Bearing amp Coupling Manufacturers Focus
onDEVELOPING Economies
amp EFFICIENCY InnovationBy Amy W Richardson
2 January 2015
Flow Control Magazine
|
gy
Anew study from Frost amp Sullivan (wwwfrostcom) fore-
casts steady growth for the overall bearings and couplings
market based on rapid industrial development in high-growth
regions Specifically Frost predicts development in Mexico
Indonesia Nigeria Turkey Brazil Russia India and Chinawill help boost the bearings amp couplings market from $2206
billion in 2013 to an estimated $2676 billion in 2018
The development of maintenance-freeor predictive technologies will helpboost growth in the bearings market For example SKF is developing products that will automatically notifyusers when a bearing or mechanicalrotating component is approachingthe end of its useful life Pictured hereis an SKF Microlog analyzer a por- table condition monitoring tool
COURTESY SKF
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
improved productivity through simplified solutions The powerful technology and tools ensure repeatable
reliable accurate measurements Easier access to process data allows for better troubleshooting process
optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
For daily product notes visit the lsquoFeatured Productsrsquo section flowcontrolnetworkcom
ON THE WEB
1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3845
FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
and benefits as well as grids of
instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
services provided for the
mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
Brought to you by Beamex
Your Source For Fluid Handling Videos
Go towwwflowcontrolnetworkcomfreeinfo
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Select advertisements thatinterest you
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1
2
3
4
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Follow these 4 steps to receive freeproduct information from suppliers
FREE
FEATURED VIDEO How to Calibrate aPressure Measurement Loop
For more information about FlowTube
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4245
THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
Name ________________________________________________________________
Title _________________________________________________________________
Company _____________________________________________________________
AddressCityStateZip __________________________________________________
______________________________________________________________________
Phone ________________________________________________________________
E-Mail ________________________________________________________________
One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545
![Page 8: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/8.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 845
The new Ultratrade 8c The capability and performance
your market demands
Copyright copy FMC Technologies Inc All Rights Reserved
FMC Technologiesrsquo Ultra 8c ultrasonic owmeter shares the advanced technology
of the next generation Smith Meterreg Ultra Series meters With its touchscreen
interface upgradable memory and high-speed processor the Ultra 8c provides
cutting-edge performance and diagnostic ability And with additional measurement
paths the Ultra 8c has even better cross-ow and swirl compensation for improved
accuracy and repeatability Whether for leak detection or custody transfer theUltra 8c gives you the assurance of superior performance in the eld even for the
most viscous crude oils in todayrsquos market
For more information visit wwwfmctechnologiescomultrafc
wwwfmctechnologiescom
Write in 6 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 945
20 Years of Flow Control This
year marks the 20th Anniversary of
Flow Control magazine Launched
in 1995 with the aim of serving technical
professionals involved with designing oper-
ating and maintaining fluid handling systems in a wide range of
industries Flow Control has leveraged its many years of experi-
ence to establish a unique niche and reputation for providinghigh-quality information to you our subscribers I congratulate everybody who helped
Flow Control get to where it stands today Herersquos to another 20 years of success
Training Time Itrsquos a new year and we have two new
training opportunities for
you to enhance your skillset in 2015
Regular Flow Control columnists Da-
vid W Spitzer and Larry Bachus will
be presenting three-day courses on
Flow Measurement and Pumping
Systems respectively I encourage you and your colleagues to take ad-
vantage of these important training
opportunities For more details see
flwctrlcomflowseminar amp
flwctrlcompumpguy
Oil amp Gas Gender Gap Results of a
new global workforce survey conduct-
ed by OilCareerscom and Air Energi
show a gender gap in the oil amp gas industry
persists despite ongoing efforts to recruit more
women into the industry According to hiring
managers the
top three factors
that significantlycontributed to
the gender gap
in the oil amp gas
industry are
1 A lack of women entering the industry (55
percent)
2 An industry culture created by a male-domi-nated environment (53 percent)
3 The logistics requirement ie travel shift
and working patterns in the field (30 percent)
For more on this story and an infographic seeflwctrlcomog_gendergap
Rockwell Automation Fair 2014 Our colleagueKevin Parker at Processing magazine attended the
annual Rockwell Automation Fair Nov 9-10 in
Anaheim Calif Parker gleaned some interesting perspec-
tive on key trends in process automation including
1 Hardware and software are more blended than ever
2 Fog computing (a kind of cloud computing) is making
headway in industrial engineering environments where latency is a critical concern
For Parkerrsquos full report from the Automation Fair see flwctrlcomrockwellfair2014
DITORrsquoS FILE
6 | January 2015
Flow Control Magazine
4 Flow Things You Need to Know
GROUP PUBLISHERPROCESSINGFLOW CONTROL
MICHAEL C CHRISTIAN | (908) 507-5472mikecgrandviewmediacom
NATIONAL ACCOUNTS MANAGERJIM SEMPLE | (908) 963-3008 jsemplegrandviewmediacom
EXECUTIVE DIRECTOR OF CONTENTMATT MIGLIORE | (610) 828-1711
mattgrandviewmediacom
MANAGING EDITOR AMY W RICHARDSON | (205) 408-5050
arichardsongrandviewmediacom
COLUMNISTS
LARRY BACHUSDAVID W SPITZER JESSE YODER
ART DIRECTORJULIE FLYNN
juliegrandviewmediacom
MANAGER - DIGITAL OPERATIONSMARY BETH ROMANO
SUBSCRIPTION amp REPRINT REQUESTSflowcontrolhalldatacom
Administrative TeamGENERAL MANAGER
BARRY LOVETTE
CHIEF OPERATIONS OFFICERBRENT KIZZIRE
VICE PRESIDENT OF FINANCEBRAD YOUNGBLOOD
VICE PRESSIDENT OF B2B GROUPMIKE WASSON
CHIEF REVENUE OFFICERCHRIS DOLAN
VP AUDIENCE DEVELOPMENTDELICIA POOLE
AUDIENCE DEVELOPMENT MANAGER ANNA HICKS
DIGITAL AUDIENCEDEVELOPMENT ANALYST
STACY BARNES
EDITORIAL ADVISORY BOARDLarry Bachus Bachus Company IncGary Cornell Blacoh Fluid Control
Jeff Jennings Equilibar LLCMitch Johnson JMS SoutheastPeter Kucmas Elster Instromet
Jim Lauria Water Technology Executive
John Merrill PE EagleBurgmann IndustriesSteve Milford Endress+Hauser US Tom OrsquoBanion Emerson Process
Management Micro MotionDavid W Spitzer PE Spitzer and Boyes LLC
Tom Tschanz McIlvaine Company John C Tverberg Metals and Materials
Consulting EngineersJesse Yoder PhD Flow Research Inc
WINNER
WINNER WINNER
PERSPECTIVES FROM THE MONTH THAT WAS IN THE WORLD OF FLOW CONTROL
WINNER WINNER
THE
NETWORK
1
2 3
4
1 9 9 5 - 2 0
1 51 9 9 5
- 2 0 1 5
20th20th
Matt Migliore Executive Director of Content MattGrandViewMediacom
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1045
Endress+Hauser Inc
2350 Endress Place
Greenwood IN 46143
infousendresscom
ww wusendresscom
Sales 888-ENDRESS
Service 800-642-8737
Fax 317-535-8498
Guided wave radar level products - built for safety precision and efficiency
bull Reliable non-contact measurement even for changing process conditions
bull HistoROMreg data management - concept for fast and easy
commissioning maintenance and diagnostics
bull Multi-Echo Tracking evaluation - highest reliability even with the
presence of obstructions in the vessel
bull Hardware and software developed according to IEC61508 up to SIL3(in homogeneous redundancy)
bull Seamless integration into control or asset management systems
bull Worldrsquos easiest proof test concept for SIL saves time and cost
wwwusendresscommicropilot-radar-level
The newest generation of Micropilot
Taking your process to the next level
Write in 7 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1145
HE OUTLOOK | News amp Notes
1 ISO15848 ldquoMeasurement test and qualification proce-
dures for fugitive emissionsrdquo
a Part I ndash ldquoClassification system and qualification proce-dures for type testing of valvesrdquo
b Part II ndash ldquoProduction acceptance test of valvesrdquo
2 API 622 ldquoType Testing of Process Valve Packing for Fugitive
Emissionsrdquo
3 End-user defined fugitive emission reduction requirements
Key aspects of valve testing per API 624 include
The standard covers rising and rising-rotating stem
valves up to 24rdquo diameter
Class 1500 valves are not covered
The test medium is methane
310 test cycles are required with three thermal cycles Temperature application range is from -29 C to 538 C
with last cycle 10 cycles user-defined (can be -45 C)
Re-tightening of gland bolts is not permitted during test
Valve stem test orientation is vertical
Several valves must be tested to achieve API 624 com-
pliance Similar industry principles applied to test valves
qualify two nominal sizes smaller one size larger and one
pressure class below
Allowable leakage is 100 PPM maximum
Gate and globe valves need to be tested separately
For example Gate Valves per API602 four tests API600
eight tests (up to 20rdquo diameter) API 603 eight tests andfor Globe Valves per API 602 four tests
Test valves should be production valves not specially
manufactured test valves
As a result of the release of API 624 testing companies have
been gearing up for an increase in the number and size of
test valves and new test houses are coming to market Withthis in mind implementation of API 624 needs to be carefully
monitored and claims from valve manufacturers should be
validated by requesting to view test results Important factors
to be mindful of include
Number of cycles on some valves could be detrimental
to packing as certain smaller size valves donrsquot come with
grease ports to keep the stem lubricated all of the time
Test failures of valve stem threads yokes and glands
Grease traps into packing and causes leakage
At higher temperatures a few greases create volatile
organic compound and burn off
Testing in vertical generates more heat in yoke area
Certain challenges need a good testing company that has
experience in testing on fugitive emissions and provides
guidelines to manufacturers in terms of use of packing valve
grease testing requirements etc
A preliminary survey was conducted with end-users regard-
ing current utilization and application of API 624 For a sum-
mary of responses from this survey visit flwctrlcom1oWijWz
Gobind Khiani PEng is with Fluor Canada Ltd Khiani has
spent 20-plus years in the energy and power business and 10-
plus years in the Western Canadian oil and gas industry Hecan be reached at 403 850-6982 or gobindkhianifluorcom
Valve Standards UpdateEnd-users ramp up compliance efforts for API 624
as new specifications emerge on the horizon
8 | January 2015
Flow Control Magazine
By Gobind Khiani
In the May 2014 issue of Flow Control (page
16) the new standard API 624 ldquoType Testing
of Rising Stem Valves Equipped with Graphite
Packing for Fugitive Emissions First Editionrdquo was
addressed This standard which was published
and put into effect in February 2014 estab-
lishes guidelines for testing industrial valves for
emissions compliance Since the publication ofthe May article further requests from industry
have spurred the creation of another specifi-
cation API 641 ldquoType Testing of Quarter-Turn
Valvesrdquo and an API ldquoPiping and Valvesrdquo commit-
tee has been formed Regulators and end-users
are also working on
1992 1998 2003 2008 2013 2020
4
35
3
25
2
15
1
05
0
M i l l i o n o f
t o n n e s y e a r Will API 624
have a stepeffect in reducing
fugitiveemissions
Global valve fugitive emissions
End User response at best
End User response actual
S O U R C E G O B I N D K
H I A N I
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1245
Intelligent Features to Boost Global WaterDesalination Pumps Market
The Global Water Desalination
Pumps Market is expected to grow
at a CAGR of 77 percent from 2015 to
2019 according to a new report from
TechNavio (wwwtechnaviocom)
The report shows demand for water
treatment has increased significantly in
developing countries where fresh wa-
ter resources can be scarce Providing
clean and potable water to huge popu-
lations has become a priority which is
pushing the demand for water desalina-tion pumps in the market according to
TechNavio
The report emphasizes the emer-
gence of intelligent pump systems as
a major driver of market growth In-
telligent pumps possess the ability to
regulate flow and pressure and these
systems can automatically adjust to
process and pump system changes
ldquoIntelligent pump systems are be-
ing adopted by many manufacturers
because of the high level of fault toler-
ance ability which leads to a significant
reduction in the total cost of owner-
shiprdquo said Faisal Ghaus vice president
of TechNavio in a news release ldquoThe
adoption of these systems will also
help industries comply with current Eu-
ropean Union regulations in relation toreduction in energy consumptionrdquo
The growing demand for clean wa-
ter worldwide will continue to augment
the demand for water desalination sys-
tems which will propel the Global Water
Desalination Pumps Market during the
forecast period
trendlines
wwwflowcontrolnetworkcom January 2015 | 9
Write in 8 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
Intelligent pump sys-tems are being adopt-
ed by many manufac-
turers because of the
high level of fault tol-
erance ability which
leads to a significant
reduction in the total
cost of ownership
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1345
HE OUTLOOK | News amp Notes
10 | January 2015
Flow Control Magazine
Hydraulic Fracturing WaterTreatment amp Reuse Expected to Soar
Wastewater treatment spending for
hydraulic fracturing is expected to
grow almost three-fold from $138 mil-
lion in 2014 to $357 million in 2020 in
the US according to a new report from
Bluefield Research
The US hydraulic fracturing industry
consumes over 1 billion barrels of wa-
ter annually producing 450ndash500 mil-
lion barrels of contaminated water for
disposal with only about 14 percent
treated and reused Bluefield cites watersupplies increasingly at risk tighter regu-
lations emerging in key states and costs
of disposal on the rise as factors con-
tributing to the substantial rise in water
treatment and reuse which is expected
to account for 27 percent of total pro-
duced and flowback water by 2020
Overall the US hydraulic fracturing
industry will spend $638 billion in 2014
on water management Water transport
and disposal costs will account for 66
percent of the total water managementspent this year with treatment compris-
ing roughly 2 percent
Bluefield reports water scarcity in
Western US states has had little im-
pact to date on fracturing water supply
but that is likely to change if droughts
persist Meanwhile state regulators are
beginning to tighten control of produced
water disposal In Pennsylvania where
policymakers in 2010 placed discharge
limits on wastewater from unconven-
tional oil amp gas operations statewide
treatment and reuse rates for the Mar-
cellus jumped to 90 percent in 2014
The increasing cost of transport and
injecting water into wells mdash now ac-
counting for 66 percent of water servicesspending mdash and the improving cost
structures of treatment provide another
driver of reuse Bluefield reports Well
operators that employ treatment and re-
use solutions spend on average $880
per barrel of water used compared to
$1020 per barrel of water trucked and
injected into wells although cost com-
parisons are site specific
ldquoFracking has been the Wild West for
the US water industryrdquo said Reese Tis-
dale president of Bluefield Research ina prepared statement ldquoThere are three
reasons for this first there has been
an explosive build-out of fracking well
installations now surpassing 126000
Second there has been a lack of clear
regulation on water management in key
markets And third there is not a one-
size-fits-all treatment solution for frack-
ing meaning solutions providers have
had to ascend a steep learning curve
to treat the variable wastewaters that a
single well is capable of producingrdquo
Tisdale notes that these inhibitors
while still acute are beginning to take on
a new form This is partially due to signifi-
cant gains in water management experi-
ence realized adoption of more efficientwater management strategies among
well operators and the emergence of
new policy mechanisms from regulators
that are playing catch-up with the fast-
moving hydraulic fracturing industry
trendlines
Treatment2
Disposal
6
Supply10
Storage22
Transport60
US $638Billion
S O U R C E B L U E F I E L D R
E S E A R C H
Write in 23 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
Industry-Leading
Warranties
Temperature Measurement Solutions
bull Probe type industrial RTDsbull Electronic temperature switchtransmitter bull Vapor-actuated remote thermometersbull Digital temperature indicatorsbull Platinum resistance temperature transmitterbull Compact OEM temperature transmitter bull Industrial amp instrument type bimetal thermometersbull Thermowells
1010 West Bagley Road I Berea Ohio 44017 I P 4402430888 I F 4402433472wwwnoshokcom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1445
New Technique Could ReduceEnergy Required for Oil Refinement
UK scientists have developed a
technique they say has the poten-
tial to dramatically reduce the amount
of energy required for the refinement
of crude oil
Professor Martin Schroumlder and Dr
Sihai Yang from The University of Not-
tingham (wwwnottinghamacuk ) have
led a multi-disciplinary team of scien-
tists from Nottingham the Science and
Technology Facilities Councilrsquos (STFC)
ISIS Neutron Facility Oak Ridge Na-tional Laboratory and Diamond Light
Source to discover a porous material
that works like a chemical sponge to
separate a number of important gases
from mixtures generated during crude
oil refinement
According to a news release from
The University of Nottingham the ex-
isting industrial process uses ldquohuge
amounts of energy to separate and pu-
rify these gases so the new technique
has the potential to revolutionize the oil
industry by significantly reducing car-
bon emissions and making the process
more environmentally friendlyrdquo
Commercially UsefulCrude oil is a raw material that is
refined to produce fuel for cars toheat homes and to create polymers
and other useful materials It is made
up of a complex mixture of hydro-
carbons (chemical compounds that
contain only hydrogen and carbon) of
which certain components are espe-
cially commercially useful
One industrial process used to
achieve hydrocarbon separation is
called ldquocryogenic distillationrdquo which is
widely used worldwide and uses vast
amounts of energy to generate the high
pressures and cryogenic temperatures
required to ensure efficient separation
research amp development
wwwflowcontrolnetworkcom January 2015 | 11
PLASTIC CONTROL VALVES FORALL YOUR CORROSIVE APPLICATIONS
PO Box 938 bull Angleton TX 77516Tel (979) 849-8266 bull wwwcollinsinstcom
Collins plastic control valves are
highly responsive control valves
designed for use with corrosive
media andor corrosive atmos-
pheres
Collins valves feature all-plastic
construction with bodies in PVDF
PP PVC and Halar in various body
styles from 12 - 2 with Globe
Angle or Corner configurations and
many trim sizes and materials
Valves may be furnished without
positioner for ON-OFF applications
Call for more information on our
plastic control valves
Write in 9 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1545
of hydrocarbon mixtures into pure components
However researchers say an innovative solution may
have come in the form of a novel chemical sponge This
porous material a metal-organic framework was devel-
oped by the same team at Nottingham just two years ago
Now in research published in Nature Chemistry for the
first time scientists have proven that it can be used toseparate hydrocarbon mixtures without the need for high
process pressures or very low process temperatures
Reusable MaterialsMade from cheap organic materials aluminum nitrate
salt and water the porous material called NOTT-300 is
able to adsorb different gases found in mixtures of hydro-
carbons at different rates making it possible to sepa-
rate them and extract the most useful ones NOTT-300
requires less energy to function than existing methods
as it operates at ambient temperatures and normal pres-
sures researchers say The gases that are adsorbed intoNOTT-300 can be removed without a significant energy
input and therefore the material can be easily reused
The team of scientists from Nottingham used Diamond
the UKrsquos synchrotron science facility as well as STFCrsquos
ISIS Neutron Facility and Oak Ridge National Laboratory
the UKrsquos and USArsquos world-leading neutron facilities re-
spectively to prove that the sponge works under real-life
conditions
Professor Martin Schroumlder Dean of the Faculty of Sci-
ence at Nottingham said in the news release ldquoIt is a very
important to be able to separate different hydrocarbons ef-
fectively and efficiently with low-energy consumption Po-rous solids such as the metal-organic framework system
studied here represent important materials for the future
development of low-energy separation technologies We
are most grateful to our collaborators at ISIS Neutron Fa-
cility Oak Ridge National Laboratory and Diamond Light
Source in bringing this work to fruitionrdquo
Significant Impact on Oil IndustryDr Sihai Yang the winner of Diamond Young Scientist
and BTM Willis Prize is a Senior Research Fellow at
Nottingham He led the project together with Professor
Martin Schroumlder Yang said ldquoWith the help of advancedcentral facilities like Diamond ISIS and ORNL we have
developed a new separation technique which can poten-
tially reduce the energy usage associated with oil petro-
leum and chemical industries which require the separa-
tion of raw hydrocarbons from crude oil
The discovery of the new material NOTT-300 could
have a significant impact on the oil industry by removing
the necessity for some energy-intensive refinement pro-
cesses researchers say
The research was funded by Engineering and Physical
Sciences Research Council (EPSRC) the European Re-
search Council (ERC) The University of Nottingham andLeverhulme Trust
12 | January 2015
Flow Control Magazine
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THE OUTLOOK | News amp Notes
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1645
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 174514 | January 2015 Flow Control Magazine
PPLICATIONS CORNER | Process Instrumentation
This is the final article in a series based on the troubleshoot-
ing of a mysterious unit shutdown due to flowmeter perfor-
mance problems
If yoursquove followed this column for most of 2014 you know
that what should have been a liquid ammonia stream to the
feed plant became problematic due to the occurrence of
bubbles of ammonia gas These bubbles caused an ultrasonic
flowmeter in a unit to indicate zero flow and caused the reactor
to scram (shut down) under warm operating conditions The source of the bubbles was traced back to the pres-
sure drop associated with a control valve located at the
exit of the liquid ammonia tank farm
This issue was resolved by identifying the problem
and fixing it at its source This was a pragmatic ap-
proach at the time (early 1980s) given the operation
of the cooling system in the unit and the limited selec-
tion of applicable flowmeter technologies
By the early 1990s changes were implemented that elim-
inated all process cooling requirementsmdashexcept for the small
jacketed cooler upstream of the liquid ammonia flowmeter In
other words after these changes the entire cooling system
would be operated and maintained to cool a few meters of
one small ammonia pipe Coincidently at about the same
time Coriolis mass flowmeters became more mature and
could reasonably measure the mass flow of liquid streams
with homogeneous low levels of vapor
The convergence of these two events resulted in another
approach to the problem that was not available in the early
1980smdashie install a Coriolis flowmeter that could operate in
the presence of bubbles The purchase and installation of a
Coriolis mass flowmeter was given high priority given its im-pact on unit operation economics and safety (by eliminating
the ldquomidget-makerrdquo (see March 2014 page 14))
Plant requirements and the technology that can meet
plant needs keep changing An excellent solution today can
become outdated in just a few years However there are few
substitutes for understanding fundamentals when addressing
a problem In other words there can be more than one way
to skin a cat FC
wwwspitzerandboyescom
Problem Solved AgainA Coriolis mass flowmeter provides a better solution
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1384 POMPTON AVENUE CEDAR GROVE NEW JERSEY 07009
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bull Constant pressure enhances
pump performancebull Prevents overpressure in
piping system
bull Wide range of pressuresettings
bull PTFE shaft and diaphragm designs
bull 1 4rdquo - 3rdquo sizes in PVC CPVC PVDFPolypro and PTFE
bull First State approved
thermoplastic valve for
anti-siphon applications
Write in 10 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
David W Spitzer
Ammonia Gas | Coriolis Flowmeter | David W Spitzer | Scram | Troubleshooting
FLOWSTREAM Find related content flowcontrolnetworkcom
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and Boyes
LLC offering engineering seminars strategic marketingconsulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer can be reached at 845 623-
1830 or at wwwspitzerandboyescom
The purchase and installation of a
Coriolis mass flowmeter was given
high priority given its impact on unit
operation economics and safetyldquordquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1845
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7232019 Flow Control January 2015
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Process improvements to increase yield or cut manufactur-
ing costs typically require enhanced process control but the
installed base of measurement instrumentation in a process
plant may simply be unable to facilitate improvements because
of age inadequate performance or unreliability Maintenance
cost and unscheduled process downtime for an aging process
plant can be very damaging to the balance sheet Upgrading
to new more accurate and more reliable instrumentation can
be prohibitively expensive New plant construction must alsomaintain a focus on optimizing costs for the process control
infrastructure The budget approval decision for new plant
construction must weigh such costs against projected market
conditions for the products that the plant is intended to manu-facture In todayrsquos volatile global marketplace return on invest-
ment calculations for plant upgrade or new plant construction
projects may go through several iterations before the trigger is
finally pulled or indeed not pulled
This article describes advances in two-wire instrumenta-
tion specifically in relation to flowmeters that have taken
place in the past few years and the significant cost benefits
that this new technology can realize for plant builders and op-
erators in terms of capital investment and cost of ownership
The Significance of Two-Wire Loop Power
A survey involving 204 participants in the chemical indus-try across Germany Switzerland the UK Canada and the
United States (Manfred Koenig PhD KIM Ludwigshafen
Germany 2006) revealed an 87 percent preference for two-
wire instrumentation versus four-wire in process applications
and 89 percent for utilities This overwhelming preference
may stem from the fact that older process plants were built
with two-wire twisted-pair cable networks connecting all
process units and measuring instruments together in an
overall plant control scheme
However these existing cables are relatively unsophisti-
cated and incapable of supporting anything but low-energy
instrumentation that is insensitive to interference from otherelectrical sources that might be sharing the same cable con-
duit Further the low energy levels supported by these two-
wire loops are more easily rendered safe in terms of explo-
sive risk in hazardous areas containing flammable materials
Many older process plants are also likely to have a significant
installed base of flowmeters employing pre-war (pre-1945)
technology such as positive displacement (PD) turbine vari-
able area (VA or Rotameter) and differential pressure (dP)
Market data firm Flow Research Inc (wwwflowresearch
com) indicates collectively a future compound negative annual
growth rate approaching minus 3 percent to 5 percent for PD
turbine and VA flowmeter types while dP is expected to keeppace with market growth (World Market for Flowmeters 2010)
YSTEMS DESIGN | Flow Measurement
16 | January 2015
Flow Control Magazine
The Two-Wire
ADVANTAGENew wiring options enable modern instrumentsto drive cost savings in existing plant systems
By Steve Milford
Advances in two-wire instrumentation have enabled mod- ern technology to be employed to the advantage of older
plant and process systems
Some chemical manufacturing plants are
competing for survival not only externally
against other global companies but also
internally among the global facilities of theirown company Other industry sectors face
similar challenges
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2045wwwflowcontrolnetworkcom January 2015 | 17
The Need to Replace Older TechnologiesUntil the 21st century two-wire loops were only able
to support these relatively unsophisticated instruments
which convert their measurement by various means into a
4-20mA output or pulse signal to the control system The
more advanced post-war flowmeter technologies such as
Coriolis ultrasonic or electromagnetic flowmeters have
until just eight years ago required a dedicated power sup-
ply for their function in addition to the output loop and
thus a four-wire infrastructure was required as a minimum
Therefore upgrading older two-wire meter devices to moremodern four-wire technology could require significant
expenditure in terms of the installation of separate power
cables and supply modules
There was a major breakthrough in 2006 when a true
two-wire loop-powered inline liquid ultrasonic flowmeter
was introduced (Figure 1) The nature of this breakthrough
was innovation in device power management This was the
missing piece up to that point because to be a true loop-
powered device the meter had to directly provide a full 16
mA span using less than 36 mA of remaining loop current
and less than 1 Watt of electrical energy The flowmeter
operated on a single 4-20 mA HART two-wire loop wasremotely powered by a DC supply was certified Class 1 Divi-
sion 1 and could be deployed as Intrinsically Safe through
the use of an approved safety barrier
A true two-wire loop-powered Coriolis flowmeter followed
in 2011 (Figure 2) employing a new and more advanced
common electronics platform A two-wire loop-powered inline
ultrasonic flowmeter for low-pressure gas was introduced in
2012 and a second two-wire loop-powered Coriolis meter fol-
lowed in 2013 offering improved measurement performance
and an additional high-performance meter tube material
Electromagnetic and vortex flowmeters had already been
available for some years in two-wire loop-powered form butimproved performance resulted as these designs were incor-
COURTESYENDRESS+HAUSER
Figure 1 A two-wire ultrasonic flow- meter released in 2006 operated ona single 4-20 mA two-wire loop
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I I I I LL I
I I I I LL I
copy COPYRIGHT 2015 OMEGA ENGINEERING INC ALL RIGHTS RESERVED
1-888-826-6342
Prices listed are those in effect at the time of publication and are subject to change without noticePlease contact OMEGArsquos sales department for current prices
FPD3000 SeriesStarts at$630
FPD3300 SeriesStarts at
$790
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OSXL-TIM3$999
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Positive Displacement Flow Meterfor Fuels and Oils
bull Aluminum Bodybull FKM Sealsbull Temperatures up to
80ordmC (176ordmF)bull NPT or BSP Threadsbull DIN JIS or ANSI
Connection (Availableon 1 and Larger Sizes)
Positive DisplacementFlow Meter for Solvents
Thermal Imaging CameraFor Inspection andFactory Diagnosis
Note Not for ExportUSA Only
Your One-StopSource for Process
Measurement and Control
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 214518 | January 2015
Flow Control Magazine
porated into their new common electron-
ics platform in 2013 So all the ldquomodernrdquo
flow measurement technologies mdash that
is to say those introduced post-war mdash
have become available as two-wire loop-
powered devices with one exception
namely thermal mass (thermal disper-
sion) meters Unfortunately the power
requirements for this technology exceed
what is currently deemed possible withtwo-wire loop-power management
Payback forTechnology UpgradeConsider a 1rdquo process line
containing a liquid process
ingredient costing $1lb at a
mass flowrate of 150 lbmin-
ute We have $150minute
flowing in the line translating
to $9000hour and $72000
per eight-hour shift That cal-culates further to $360000
per five-day working week and
for a working year of 40 weeks for
example that is $144 million Assume
the existing device is a turbine flowmeter
Now imagine a two-wire loop-
powered Coriolis mass flowmeter is
installed in place of the existing meter
The line would need to be drained and
probably one process flange replaced
allowing the Coriolis to fit mechanically
in place of the turbine However thetwo-wire loop already used for carrying
the existing meterrsquos flow signal to the
control room can be used unaltered
for the complete electrical installation
aspects of the Coriolis flowmeter
The upside of the change is signifi-
cant and clear cut Assuming the exist-
ing meter measurement uncertainty was02 percent of reading then measure-
ment uncertainty improves through use
of Coriolis to 01 percent of reading
giving a 01100 x $14400000 im-
provement in control of the ingredient
annually or $14400 A two-wire Coriolis
mass flowmeter with 01 percent mass
flow accuracy would be paid for in ap-
proximately 6-8 months In practice the
improvement in measurement uncer-
tainty would be greater as the operator
would gain temperature and density in-formation from the Coriolis and the mea-
surement would be devoid of any fluid
property dependence Viscosity change
for example can have a major impact on
turbine meter performance Mechanical
wear and tear that turbine meters even-
tually experience which causes them to
under-register flow is precluded by mod-
ern devices like Coriolis
Furthermore if the process ingredient
was being blended with another then ad-
ditional process improvements could berealized through in-line blending control
using Coriolis technology for final density
as the control point It is possible to have
dual 4-20 mA outputs from two-wire
loop-powered meters but as the main
4-20 mA output representing the prima-
ry variable is also HART then an external
HART Loop Converter or HART IO card in
the control system can provide second-
ary tertiary and quaternary variables as
4-20 mA signals A Coriolis meter is trulya multi-variable device Certain two-wire
devices are also available with Profibus
or Foundation Fieldbus communication
Cutting Wiring CostsIn 2003 WIBEXERA (International
Instrument Usersrsquo Associations) Report
T 2732 X 03 was published and it pro- vided an average survey of prices quoted
in projects at that time for the provision
of power supplies for four-wire instru-
ments The price ranged from euro1200
to euro1800 per instrument depending
upon design and plant characteristics
for an average cost of euro1500 (about
$2000) It would be reasonable to
assume an inflationary factor of 2 per-
cent per annum giving an approximate
current-day figure of $2500
From another source within thechemical industry an estimation of
$40foot to $50foot was given for in-
stallation of four-wire cabling For a
linear 50-foot cable run with for ex-
ample a 10-foot vertical at each end
this equates to $3150 Actual costs
and budget estimates have been given
as high as $10000
The Extent of the Opportunity The modern post-war flow measure-
ment technologies have different powerrequirements and consequently they
are not all available for the
same size range in two-wire
loop-power form For example
two-wire Coriolis flowmeters
are limited to 2rdquo diameter
electromagnetic and inline
low-pressure gas ultrasonics
are limited to 8rdquo and vortex
and inline liquid ultrasonic are
limited to 12rdquo
Nevertheless for thechemical industry in particu-
lar perhaps two-thirds of the
process pipes in a plant will be no larger
than 2rdquo and even when the host process
pipe is larger a correctly sized flowmeter
can still be less than 2rdquo There is consid-
erable scope for two-wire loop-power to
deliver value for flow measurement ap-
plications with total safety
The virtues of Coriolis technology
have been covered but what about
other two-wire technologies An elec-tromagnetic flowmeter in two-wire form
YSTEMS DESIGN | Flow Measurement
In todayrsquos volatile global mar-
ketplace return on investment
calculations for plant upgrade or
new plant construction projects
may go through several itera-
tions before the trigger is finally
pulled or indeed not pulled
ldquo
rdquo
COURTESYENDRESS+HAUSER
Figure 2 Two-wire Coriolis flowme- ters became available in 2011
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2245
can be used on water wastewater or
a light water-based slurry provided the
fluid has around a 20 microSeimenscenti-
metre (microScm) electrical conductivity
A magnetic flowmeter is full bore un-
less flowrates dictate a reduced meter
size in the interests of performance and
so there are no intrusions into the flow
stream and no pressure loss An accu-
racy of 05 percent of reading is normal
from a two-wire magnetic meter and a
modest five diameters (5D) of straight in-let run is needed to avoid error from up-
stream flow disturbances When the fluid
exhibits insufficient conductivity then
the same performance and installation
requirements can be met by an inline ul-
trasonic flowmeter provided the liquid is
essentially clean and bubble-free
For gas or steam applications a vor-
tex meter is the normal choice Using a
built-in temperature sensor a two-wire
loop-powered vortex meter can calculate
mass flow of saturated steam using in-ternal steam tables An external pressure
input allows mass flow of steam to be ac-
curately calculated even when saturated
steam becomes superheated as can oc-
cur downstream of a pressure regulating
valve With mass flow known the vortex
meter can calculate energy and heat flow
A new and exciting development is
the ability of the vortex meter to indicate
wet steam and calculate dryness frac-
tion or steam quality For safety and ef-
ficiency saturated steam should be dry
and free from condensate that is to say
it should possess a high steam quality
factor However the dry or wet state of
saturated steam can sit on a knife-edge
and shift to the opposing state due to
the slightest change in process condi-
tions Rapid and reliable indication of
this change of state is now available
Perhaps the most astonishingachievement in the power management
of two-wire loop-power flowmeters is
that of the ultrasonic biogas meter It is
now possible not only to measure the
flow of wet dirty variable composition
and low-pressure anaerobic digester
gas landfill gas and coal bed methane
gas with a two-wire loop-powered ultra-
sonic flowmeter but also the same de-
vice uses an inbuilt temperature sensor
in combination with measured sound
velocity to calculate methane contentcalorific value and energy flow
Technology to Take UsForwardModern flow technologies provide instru-
ment engineers with vital self-monitoring
information The format of such infor-
mation is easier to understand and act
upon when presented in accordance
with harmonized international guidelines
for online plant asset management eg
NAMUR Standard 107
Continuous plain-text self-diagnostic
and process-related information with
suggested remedies (Figure 3) make it
possible for instrument engineers andoperators to take action at the appro-
priate time mdash immediately or during
the next scheduled shutdown mdash saving
time and money by knowing the exact
health of their measuring point and the
probable actions required to rectify any
abnormal conditions Device verifica-
tion offering third-party validated trace-
ability can be performed on demand ei-
ther locally or remotely from the control
room without the expense of a man in
the field Calibration is then avoided ordeferred without process interruption
Where a process plant has a large
installed base of older mechanical tech-
nologies the decision to embark upon a
program of replacement for plant mod-
ernization cannot of course be taken
easily There are the stocks of spare
parts to consider along with the plant
instrument technicians who are trained
on and at ease with the old devices
However a process plant that retains
the older technology going forward willbe at risk and may find it increasingly
difficult or even impossible to maintain
a cost position that competes effective-
ly in the global market FC
wwwusendresscom
wwwflowcontrolnetworkcom January 2015 | 19
Steve Milford
is a Flow Product
Business Manager
for Endress+Hauser
Inc in Greenwood
Ind He has been
involved in flow
measurement since
1983 and has been
actively involved with standards devel-
opment for flow technology within the
International Standards Organization
(ISO) and the British Standards
Institute Mr Milford can be reached
at stevemilfordusendresscom
Steve Milford
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Coriolis Flowmeter | Magnetic Flowmeter | Two-Wire | Ultrasonic Flowmeter | Vortex Flowmeter
Figure 3 A modern instrumentrsquos display module can provide continuous plain- text self-diagnostic and process-related information
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2345
The bottom line is the volume of gas under one set of
pressure and temperature conditions is not the same as it
would be for the gas under different conditions Why is thisimportant Without compensation for compressibility read-
ings taken by gas flowmeters can result in measurementsmdash
and costs to the buyermdashsignificantly lower or higher than they
should be
The flow of gas in a system can be accounted for and
reported in a number of ways such as by volume by mass
flowrate and by energy Inline turbine meters can offer both
reliability and accuracy in measuring gas flow when matched
with a monitor capable of calculating and displaying results
that have been adjusted for the nature of the gas and impor-
tantly the pressure and temperature
Measuring Flow with an Inline TurbineFlowmeter
With an inline turbine meter gas flows into the meter through
a length of piping that helps to pre-condition the flow by
reducing undesirable swirls and asymmetry Where consid-
ered necessary a flow straightener may even be installed in
line to create a uniform flow profile to the extent possible
As can be seen in Figure 1 a rotor support within the tur-
bine housing further conditions the flow and directs it through
the blades of the rotor High-precision ball bearings allow the
rotor to freely rotate on the shaft
The rotorrsquos rotational speed is directly proportional to the velocity of the fluid passing through the meter The rotor itself
incorporates magnets (or magnetic blades depending on thedesign) while the housing is non-magnetic
A proximity sensor (also known as a pickup coil) is located
in line with the rotor and detects the electrical pulses gener-
ated by the ferrous rotor spinning through the magnetic field
Each pulse represents a discrete volume of gas The out-
put frequency provides the indication of the gas flow rate and
the accumulated pulses over a specified time represent the
total volume of fluid for that measurement period
Need for Calibration The flowrate of the gas through the meter cannot be deter-
mined accurately unless the meter is calibrated The fac-tory calibration determines the meterrsquos constant known
as a K-factor which is then inputted into the gas monitor
PPLICATION NOTES | Flow Measurement
20 | January 2015
Flow Control Magazine
COMPENSATING for
Compressibility inMeasuring Gas Flow Why K-factor adjustment is essential foraccurate inline turbine flow measurement
Unlike crude oil and other liquid fossilfuels natural gas poses a challenge
in monitoring the quantity of gas flowing
through pipelines While liquids do not com-
press gases do and the mass flowrate of
gas being transmitted through gathering
lines depends on both the pressure and
temperature
By Kevin Clark
Figure 1 Internal components of a liquid turbine flowmeter
C O U R T E S Y
T U R B I N E S
I N C
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2445
Wondering Whether the
Pump Guy Seminar
Is for YouCheck out the ldquoPump Guy Insightsrdquo
video series flwctrlcompginsights
PUMP GUY INSIGHT 1NPSHa vs NPSHrmdashWhy all pumps need gauges
PUMP GUY INSIGHT 3How to Operate Your Pump at Best Efficiency
PUMP GUY INSIGHT 5Head vs Flow
PUMP GUY INSIGHT 2 Your Pumps Are Constantly Moving On Their Curves
PUMP GUY INSIGHT 4 The Role of the Pump Reliability Chain
PUMP GUY INSIGHT 6How to Read a Pump Curve
PARTNER SPONSORSFor more information and to register
for upcoming Pump Guy Seminars
visit FlowControlNetworkcomPumpGuy
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2545
PPLICATION NOTES | Flow Measurement
22 | January 2015
Flow Control Magazine
Gas flowmeters measure the actual volume of gas passing
through the meter per minute irrespective of pressure and
temperature1
The volumetric flowrate of a gas is often corrected to
ldquostandardizedrdquo conditions of pressure and temperature While
ldquostandardrdquo conditions can vary depending on the definition
in the US this typically means a pressure of 1473 PSIA(pounds per square inch absolute) and a temperature of 60 F
The flowrate measurement is reported in standard cubic feet
per minute (SCFM)
Compensating for changes in pressure and temperature is
critical Consider a meter system setup for flowing conditions
of 60 PSIG (pounds per square inch gauge) and 60 F and the
line pressure decreases to 50 PSIG while the temperature
remains constant The difference in SCFM between the two
is more than 15 percent which would cost the buyer more
for the gas than it should As Table 1 demonstrates even a
small variation in pressure will result in a surprisingly high er-
ror percentage
Automation of the K-Factor The K-factor is established by an initial factory calibration In
the case of a non-compensated flow monitor any variations
in pressure and temperature will result in manual adjust-
ments needed to the K-factor In order to maintain accurate
flow measurement users must monitor pressure and temper-
ature and make corresponding adjustments to the K-factor To eliminate these manual adjustments some suppliers offer
a flow monitor that automatically adjusts for any changes in
pressure and temperature
These monitors provide accurate flow measurement regard-
less of changing environmental conditions in some cases sup-
porting applications with pressures as high as 15000 PSIG and
temperatures between -350 F to 350 F with a standard accura-
cy of +-1 percent over a flow range of 05 ACFM to 650 ACFM
Final NotesDuring the operation of a flowmeter system the ability to obtain
a readout mdash and to adjust for line pressure and temperaturechanges mdash is sometimes compromised by a lack of electric
power This issue is especially true along gas pipelines in remote
areas To overcome this limitation some manufacturers have
designed low-powered flow monitors which can operate for up
to on year on a single lithium D-cell battery
It is important for users to recognize the effects of the
compressibility of gas As such the quantity of a gas flow-
ing through a gas flowmeter depends on the pressure and
temperature In order to ensure accuracy any flowmetering
system must employ a means to correct for these effects
Otherwise the readout is certain to be in error and could be
unnecessarily costing money This is particularly crucial onwellhead production and in billing scenarios FC
wwwturbinesincorporatedcom
Notations1 The measurement factor in the US is known as the
ACFM actual cubic feet per minute (Metric units are typically
ACMH actual cubic meters per hour)
Table 1 Error induced by line pressure changes
Constant Temperature with Varying Pressure
Pressure Temperature PulsesSCF Error
50 60 2556027821 1546
51 60 2517123288 1370
52 60 2479385307 1199
53 60 2442762186 1034
54 60 240720524 873
55 60 237266858 717
56 60 2339108911 566
57 60 2306485356 418
58 60 2274759285 275
59 60 2243894166 136
60 60 2213855422 000
61 60 2184610304 132
62 60 2156127771 261
63 60 2128378378 386
64 60 210133418 508
65 60 2074968632 627
66 60 2049256506 743
67 60 2024173807 857
68 60 1999697703 967
69 60 1975806452 1075
70 60 1952479339 1181 Flow Measurement | K-Factor | Measurement
Accuracy | Turbine Flowmeter
Find related content flowcontrolnetworkcomhellipSearch on
FLOWSTREAM
Kevin Clark is senior develop-
ment engineer for Turbines Research
amp Development LLC Turbine RampD is a
subsidiary and the research and techni-
cal support arm of Turbines Inc which
serves a range of industries and applica-
tions from oil amp gas to cryogenic liquids
to custody transferKevin Clark
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2645
Pumps Bearings amp Seals TECHNOLOGY REPORT
FEATURES
SYSTEMS DESIGN
The ComplicatedCase of
Compressors
withSide-Streams
24 28 32BEST PRACTICES
How PumpingSystems
AffectSealing
Performance
TECH OUTLOOK
BearingSuppliers
Drive Gains InDeveloping
Markets
wwwflowcontrolnetworkcom January 2015 | 23
S P E C I AL S E C T I O N
I S T O C K
7232019 Flow Control January 2015
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The design and operation of compressors with side-
streams has always been difficult because flow entering the
compressor needs to be mixed with the core flow already
in the compressor (compressed in section-1) in a manner
that does not degrade the aerodynamic performance of sur-
rounding sections Minimizing losses and ensuring proper
mixing of the side-stream flow and core-flow are required to
ensure effective performance of a compressor of this sort
Key considerations for an application involving compres-
sors with side-stream flow include
The plant process typically dictates the side-stream
flange pressure
The impellers upstream of the side-stream should
achieve the necessary pressure for the core-flow
The side-stream flow is typically at a temperature dif-
ferent from compressor core-flow temperature
Process plants need some degree of operational flex-
ibility ie the ability to support variations in core-flow condi-
tions and side-stream conditions
Modern process plants are usually specifying more than
one operating conditions (sometimes two or more manda-
tory conditions) which can present challenges to compres-
sors with side-streams Adding to these issues modern
compressors should operate with much higher impeller tip
The COMPLICATED CASE ofCompressors with Side-StreamsConsidering key system design requirements
to ensure operational efficiency By Amin Almasi
4 January 2015
Flow Control Magazine
|
y
g
Some compressors in certain applications
have one or more incoming side-streams
(or side-loads) that introduce side-stream
flow to mix with the core flow In other words
a radial side-stream inlet is utilized in multi-
impeller centrifugal compressors to introduce
additional gas into the mid-stage of a com-
pressor This design enables optimization in
some process plants However the flow dis-
tribution after the junction of the side-stream
and the main return channel of the upstream
section can significantly affect the perfor-mance of the next section of compressor
In most cases the pressure levels at these
side-streams should be accurately predicted
to meet the theoretical performance
Compressor station at a natural gas processing plant
R U D M E R Z W E R V E R I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2845
speeds and inlet Mach numbers compared to previous
generations of compressor technology
Likewise side-streams are now com-
monly used with medium-sized and
large-sized compressors (eg 1ndash60
MW) The costs associated with cor-
rections on side-stream compres-
sor applicationsmdashany repair
inefficient operation and power
lossesmdashwould be very high Fur-
ther compressors with side-streams
are usually sensitive and difficult
machines to operate In particular
performance curves (performance
pressures efficiency etc) are sen-
sitive to suction inlet conditionsside-stream inlet conditions vol-
ume flow ratio (side-stream vol-
ume to core-flow volume) and side-stream losses
Compressors with side-stream often perform far below
expectations The main reason is that side-stream compres-
sors are different than conventional compressors (without
a side-stream) in design and operation For a compressor
with side-streams tighter tolerances in operating conditions
must be identified and applied Uncontrolled variations of
suction pressure or side-stream pressure are major prob-
lems Another major issue is the variations of the flow ratio
(side-stream flow to core-flow)
Compressor Side-Stream amp Mixing SectionIn many centrifugal compressors the portion of the side-
stream system from the flange connection to the mixing
section is similar to a compressor inlet A great challenge
is ensuring the mixing section provides circumferentially
uniform merged-flow with minimum losses This can be
achieved via effective design of the inlet configuration and
mixing section of the side-stream compressor such that
the impeller can be maintained over the whole operating
range of the compressor In many cases while there are
mixing sections provided for the machine the flows do not
completely mix before entering the impeller of the section-2
(the impeller after the mixing section) Non-uniformity at
inlet flow to the impeller is a key concern for compressor
performance
Another consideration is a compact design of the side-
stream mixing section Specifically a mixing section with
less axial length is always preferred This axial length can af-
fect the compressor rotor dynam-
ics the rotor length and over-
all compressor performance
(design cost operation and
reliability)
The side-stream exit pressure
(side-stream pressure at inlet
of the mixing section) is mainly
a function of the side-stream
flow velocity and the pres-
sure in the previous section of
the compressor Conversely the side-
stream flange pressure can depend on
side-stream flow velocity and section-1
exit conditions Therefore the side-stream
inlet flange volume flow is a function of theflange pressure compressibility (at that
pressure and temperature) and mass flow
Some engineers assume that the side-stream flange pres-
sure is equal to the inlet pressure of the first impeller of the
section-2 This is not true The mixed total pressure can be
estimated on a mass-averaged basis using side-stream total
pressure and return channel exit (section-1) total pressure
In some designs because of the lower static pressure at
the side-stream exit the total pressure at the return channel
exit is lower even though the velocity upstream is roughly
matched for both streams The pressure usually increased
at the returned channel but it can be reduced again at the
side-stream exit While simple in nature this can have an
impact on the prediction of pressure at the side-stream exit
and overall mixing section performance Based on basic flow
principles it was usually assumed that the static pressure
was equal between both flow streams at the mixing location
While this assumption might be used in rough calculations
the accurate simulations have shown this assumption is not
true In fact there are some points (for instance the shroud
wall at the exit of the return channel and the hub wall at
the exit of the side-stream) where this assumption is true
However this is not valid for all locations There are pressure
changes that occur from a side-stream flange to the inlet
of the next section (section-2) which depend on different
factors The first factor is the frictional losses due to side-
stream geometry from side-stream flange to plenum mix-
ing section etc The other factors are pressure changes due
to local curvature and geometry details of mixing section
Another consideration is the operation of a compressor
with side-stream at part-load The performance of the side-
wwwflowcontrolnetworkcom January 2015 25
Figure 1 An example of a centrifugalcompressor with side-stream
COURTESY SIEMENS
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 29456 January 2015
Flow Control Magazine
|
y
g
stream path the mixing section and
the downstream impellers when ma-
chine is operated at part-load or even
off-design operating flows will result
in additional compressor performance
problems In such a case both veloc-
ity profiles and pressure variations in
various parts (side-stream path mixing
section etc) will be different resulting
in complicated flow patterns and com-
plex aerodynamics behaviors
Side-Stream CompressorSectional Performance
Typically vendor-supplied compressor
performance curves reflect flange-to-flange performance because that is
what the plant engineers need to
evaluate the proper operation of their
system (for example from suction to
side-stream and from side-stream to
discharge) In many cases compres-
sor vendors also provide the over-
all compressor performance curves
and performance curves for section-1
(from suction to side-stream) and sec-
tion-2 (from side-stream to discharge)
Flange-to-flange data if not interpret-
ed properly can lead to false conclu-
sions about the relative performance
of individual sections of a compression
system For example if side-stream
losses from the flange to mixing sec-
tion are attributed to the downstream
section (section-2) it will cause the
downstream section (section-2) to
appear low in performance while the
upstream section (section-1) will show
high performance levels
An important behavior to con-
sider is when the actual side-stream
pressure is different than the rated
side-stream pressure When the side-
stream pressure is slightly higher than
the outlet pressure of the section-1
it (section-1) shows a relatively higher
performance compared to the real sec-
tion-1 performance In some cases
the performance of section-1 could be
considerably higher than section-2 In
other words when performance is de-
termined flange to flange the higher
flange pressure is seen as extra ldquopseu-
dordquo work done by the section (since this
is an inconsistent thermodynamic vol-
ume) resulting in a relatively high sec-
tional efficiency (section-1 shows a rel-
atively high efficiency) This is the case
for many compressors with side-stream
because the whole system is designed
(or specifically the side-stream location
is selected) in a way aimed at main-
taining the real side-stream pressure(side-stream inlet) above the section-1
outlet pressure because if the real side-
stream pressure becomes lower than
the section-1 outlet pressure the flow
may (theoretically) reverse
This is particularly important when
the side-stream mass flow is much
lower than the mass flow of core-flow
The above-mentioned reasons explain
why in many simulations calcula-
tions and performance reports related
to compressors with side-stream the
section-1 shows a relatively good ef-
ficiency and section-2 appears low in
efficiency
When the side-stream pressure is
slightly lower than the outlet pressure
of the section-1 the section-1 might
show a relatively lower performance
compared to section-2 This could oc-
cur in some recycle services where the
side-stream is actually a recycle flow
with a mass flow around two to five
times the core-flow The side-stream
(recycle) flow is returned from down-
stream of the compressor to be slightly
compressed and recycled to the down-
stream Such a recycled side-stream
compressor can present unique chal-
lenges for design and operation This
kind of machine usually needs very
special operating procedures and very
fine adjustments regarding operating
pressures and flows
Side-Stream Compressor
Performance amp Operation An important consideration is the sen-
sitivity of compressor overall perfor-
mance curve and sectional perfor-
mance curves to the flow ratio (ratio
of side-stream flow to core-flow) and
to the inlet conditions Variations in
the flow and pressure of the main
suction and side-stream inlet should
be controlled within tight tolerances
For compressors with side-stream the ASME PTC-10 code stipulates limits on
flow ratio (side-stream volume to core-
flow volume) The acceptable variation
in volume flow ratio in a compressor
with a side-stream is +-5 percent as
per ASME PTC code The requested
side-stream pressure tolerance is not
usually specified in compressor codes
but it should be around +- 2 percent
(or sometimes +- 25 percent)
Variance in flow ratio impacts the
velocity levels where the two streams
merge Significant variation in the ve-
locity profile upstream of the impeller
changes the incidence on the blade
leading edge of the following impel-
ler This change in incidence leads to a
change in sectional performance over-
all compressor performance and train
efficiency
If the flow ratio is varied between 95
percent and 105 percent (tolerances
specified in the ASME PTC-10 code)
the flange pressure changes accord-
ingly resulting in a change in the sec-
tional performance and overall perfor-
mance The sectional efficiency varies
sometimes more than +- 4 percent
This variance reduces as the flow is de-
creased toward surge However as the
flow is increased toward overload the
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3045wwwflowcontrolnetworkcom January 2015 27
variance increases up to higher values
(even in some cases three to five times
compared to variations near the surge
zone) For example in a case study
for a compressor with side-streams a
+- 5 percent variation in flow ratio and
associated changes (pressures losses
etc) the sectional efficiency reduced by
approximately 34 percent at the rated
flow at allowable operating points at
the end of curve (near the overload
ie choke) efficiency reduced by ap-
proximately 55 percent These results
show that the variation in sectional
performance and overall performance
due to flow ratio is highest at operat-ing points near the overload and low-
est at operating points near the surge
For compressors which work most of
the time at high flow (flow higher than
rated flow and discharge pressure low-
er than rated pressure) the effects of
flow ratio deviations (and subsequently
efficiency reduction) would be higher
than compressors working on the left-
hand side of curve (say with sufficient
margins near the surge)
In the compressor codes (such as
API 617) the compressor power varia-
tions should be maintained below 4
percent However in some applica-
tions clients require tighter tolerances
on the consumed power sometimes
below 2 percent (or even below 15
percent) Some studies suggest while
+- 5 percent of volume flow ratio is
suitable for performance test as per
ASME PTC-10 code some plants re-
quire tighter control on the consumed
power and compressor performance
(lower limits on the efficiency) the tol-
erances on the volume flow ratio could
be tighter than ASME PTC code In this
regard +- 4 percent tolerance can be
suggested on the volume flow ratio (ra-
tio of side-stream flow to core-flow) of
compressors with side-streams
Based on operational experiences
acceptable variations in volume flow
ratio and inlet pressures (suction inlet
and side-stream inlet) of a compressor
with side-streams are +- 4 percent
and +- 2 percent respectively
Another important consideration is
the required adjustments for the flow
ratio (side-stream flow to core-flow)
Compressors with side-stream usually
require fixed side-stream flange pres-
sures For a compressor with some variations in operation conditions (even
small changes) it is not usually pos-
sible to achieve optimum operation by
keeping the flow ratio (side-stream to
core-flow) constant The flow ratio has
to be adjusted according to the inlet
flow at which the machine is operating
in order to get the required correspond-
ing side-stream flange pressure
Thermal changes have also been
known to cause some instability in
centrifugal compressors An example is
the thermal-induced change of resid-
ual unbalance For compressors with
side-streams which feature tempera-
ture differences between core-flow and
side-stream flow the thermal behav-
ior of the compressor is usually more
complex and requires more attention
Heavy Gas ChallengeHeavy gases (such as heavy hydrocar-
bon gases eg propane propylene
MTBE (Methyl Tertiary Butyl Ether))
have very low gas sonic velocities that
produce high Mach numbers in the
aerodynamic flow paths For these
services because of high Mach num-
ber high flow coefficient stages have
very narrow flow maps characterized
by limited surge and choke margins
Compressors with side-streams in
these services present great challeng-
es This is to say the side-streams and
associated mixing further complicate
design operation and performance
prediction because the pressure tem-
perature and flow conditions at each
one of these side-streams as well
as at the exit of the machine require
stringent tolerances to optimize the
overall efficiency and performance
As such it is important to accuratelymodel design operate and moni-
tor performance characteristics of any
impellers diffusers return channels
and generally all flow-path components
in a compressor with side-stream FC
Amin Almasi
is a senior rotating
machine consultant
in Australia He is
a chartered profes- sional engineer of
Engineers Australia
(MIEAust CPEng ndash
Mechanical) and
IMechE (CEng MIMechE) holds
bachelorrsquos and masterrsquos degrees
in Mechanical Engineering and is
a registered professional engineer
in Queensland He specializes in
rotating machines including cen-
trifugal screw and reciprocating
compressors gas turbines steamturbines engines pumps subsea
offshore rotating machines LNG
units condition monitoring and reli-
ability Mr Almasi is an active mem-
ber of Engineers Australia IMechE
ASME and SPE He can be reached
at aminalmasiymailcom
Amin Almasi
Compressor | Gas Flow | Performance Curve | Side-Stream Flow
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3145
The pressure in the stuffing box
containing the packing can be estimat-
ed by the following equation
SBP = [Discharge ndash Suction] 3 + Suction
Pressure at the bottom of the stuff-
ing box will be higher than the suction
pressure but considerably lower than
the discharge pressure It should be
noted this calculation will yield a con-
servative estimate of stuffing box pres-
sure that can be further reduced by
pump design
A hole in the stuffing box serves as
a port for injecting clean fluid that cir-
culates around a lantern ring aligned
under the flush port The fluid flushes
solids back into the process to protect
the packing from abrasive wear If the
clean fluid is injected at a pressure ex-
ceeding that at the bottom of the stuff-
ing box some of it will leak back into
the process and some will leak out to
the atmosphere Recommended flush
injection pressure is 15ndash30 PSI (1ndash2
Bar) greater than the pressure at the
bottom of the stuffing box
Fluid injection is also used to lubri-
cate and cool dry-running packing that
is subject to frictional heat and to pre-
vent air from entering the pump which
reduces flow and operating efficiency
Centrifugal pumps utilize three
types of impellersmdashopen semi-open
and closed (Figures 2 3 amp 4) Open
designs prevent fluids with large solids
from clogging the impellers but at theexpense of pump efficiency Backing
plates on semi-open designs serve to
trap the fluid for more efficient opera-
tion Closed impellers are for use with
clean fluids since solids could ac-
cumulate in the eye which would re-
quire tearing down the pump to remove
them
Single-Stage CentrifugalPumpsSingle-stage centrifugal pumps typi-
cally have good bearing support of the
shaft with few run-out or ldquowhiprdquo prob-
lems However in some cases they
are subject to cavitation This occurs
in the eye of the impeller where the
fluid is under vacuum If the pressure
is low enough it will cause the material
to vaporize forming air or water vapor
bubbles As the fluid passes through
How Pumping Systems Design Affects Sealing Performance
By Chris Boss
8 January 2015
Flow Control Magazine
|
Understanding how different types of pump designs impact
sealing is critical to optimizing efficiency safety and lon-
gevity of the sealing system Used for a wide variety of media
including clear fluids solutions and slurries single-stage
centrifugal pumps are one of the most common
types (Figure 1) Fluid drawn into these pumps
enters the eye of an impeller that spins itto the outside of its container
or volute building pressure as
it moves toward discharge
Some of this fluid will work
its way behind the impeller
where it must be sealed with
compression packing or a
mechanical seal
Figure 1
Figure 2 Figure 3 Figure 4
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3245
the pump under increasing pressure
these bubbles implode sending shock
and vibration through the impeller
adversely affecting the seal This phe-
nomenon can be mitigated by running
the pump at slower speed and higher
pressure at the suction end to prevent
air from entering the fluid
Double-Ended Split-CasePumpsOperating on the same centrifugal prin-
ciple but slightly different geometry are
double-ended split-case pumps (Figure
5) Fluid enters both ends of the pump
and is directed into the eye of an impel-ler which spins it out of the volute to
discharge Packing is installed on both
the shaft and bearing ends so the stuff-
ing box is exposed only to suction pres-
sure which is usually quite low
Axial Flow Pumps Axial flow pumps operate like hydro
turbines in reverse whereby a propeller
(or axial impeller) pushes the fluid to
discharge (Figure 6)
Since the stuffing box is located
downstream of the propeller at the dis-
charge end of the pump the packing is
exposed to the full discharge pressure
Vertical PumpsVertical turbine pumps are typically
flange-mounted on a floor extending
downward into a water-filled sump
hole (Figure 7) Available as single- or
multi-stage pumps they feature an
impeller or series of impellers rotated
simultaneously by a single shaft The
impellers increase the pressure of the
upward flow subjecting the stuffing box
to full discharge pressure
Vertical pumps can be quite long so
inadequate bearing support can cause
the shaft to run out This can induce
undesirable lateral motion on the pack-
ing Worse the packing may be forced
to serve both as a bearing and a seal To
withstand these conditions the packing
should be resilient elastic and resistant
to deformation These properties rule
out packing such as graphite foil in favor
of fiber-based materials
Multi-Stage PumpsMulti-stage pumps are used for high-
pressure applications such as feeding
the boilers in steam-powered generating
plants Stuffing box pressure can vary
with pump design and number of stag-
es Designed for clean fluids and high
operating speeds these pumps typically
have high- and low-pressure ends with ahydraulic pressure equalization line run-
ning between the stuffing boxes
Like vertical pumps multi-stage
pumps feature a series of impellers to
build fluid discharge pressure In the
case of the six-stage pump pictured in
Figure 8 fluid enters at the drive end
where a stuffing box is exposed to suc-
tion pressure Channeled from one
impeller to the next through the pump
casting the fluid can reach extremely
high pressures at discharge
A second stuffing box located at the
bearing end is exposed to an intermedi-
ate pressure from the third impeller This
pressure is greater than the suction pres-
sure but much less than the discharge
pressure which can reach 2000 PSI
Fortunately the stuffing boxes in
these pumps are not exposed to dis-
charge pressures and typically see be-
low 500 PSI which is within the range
of some packing materials
wwwflowcontrolnetworkcom January 2015 29
Figure 5
Figure 6
Figure 7
Figure 8
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 33450 January 2015
Flow Control Magazine
| Gear PumpsPositive-displacement or gear pumps
operate on a different principle than
centrifugal pumps In external gear
pumps the fluid flows around the out-
side of the gears the intermeshing
of which forces it through the pump
to discharge (Figure 9) This design
makes these pumps particularly suit-
able for use with highly viscous fluids
such as resins emulsions syrups and
adhesives As such they are used for
transfer or metering applications
It should be noted gear pumps will
continue to displace fluid as long as
their shafts are turning which can pose
a problem if a clog occurs at the dis-
charge The resulting buildup of pres-
sure can blow out seals and damage
the pump Therefore most gear pumps
have pressure relief valves to divert
fluid back to the suction side for re-
circulation through the pump Internal
gear pumps operate slightly differently
but also have pressure relief valves to
prevent damage from excessive pres-
sure (Figure 10) In both external and
internal gear pumps the maximum
stuffing box pressure is determined by
these valves
Other rotating equipment includes
mixersagitators which are similar to
pumps in terms of the speeds to which
the packing is exposed There are ba-
sically three types of mixersagitators
top- bottom- and side-entry Top-entry
models are subject to the same con-
cerns about shaft run-out ldquowhiprdquo and
lateral forces on the paddles that are
encountered in some vertical pumps
Although some fluid may splash onto
the packing these mixers basically run
dry so the packing must have the abil-
ity to dissipate the resulting frictional
heat
In bottom-entry mixers the packing
is always exposed to fluid and may also
be exposed to solids requiring abra-
sion-resistance If the seal fails the en-
tire contents of the tank will eventually
drain out onto the bearings the floor
and other components under the stuff-
ing box
The packing in side-entry mixers may
be fully or intermittently exposed to flu-
id as well as side loading and vibration
Aside from media temperature
speed and other application variables
the configurations and operating prin-
ciples of rotary-type pumps exert differ-
ent forces on the seals used to keep
them from leaking These forces can
spell the difference between accept-
able seal performance and failure
Understanding these differences has
important implications that should be
taken into account to assure proper
sealing selection for long-term trou-
ble-free performance FC
wwwgarlockcom
Chris Boss is
a senior applica-
tions engineer for
Garlock Sealing
Technologies in
Palmyra NY He
has held various
positions in produc-
tion engineering
product development and applica-
tions engineering for the companyrsquos
compression packing division He
is a BSME graduate of the State
University of New York at Buffalo Mr
Boss can be reached at 800 448-
6688 or chrisbossgarlockcom
Chris Boss
Cavitation | Centrifugal Pump | Pump Packing | Sealing System
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Figure 9
Figure 10
Aside from media temperature speed and
other application variables the configurations
and operating principles of rotary-type
pumps exert different forces on the seals used
to keep them from leaking These forces can
spell the difference between acceptable seal
performance and failure
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3445
NS IDERNDUSTRIAL AUTOMATION + PROCESS CONTROL
WANT
INFORMATION
ON THE
automationindustry
SUBSCRIBE NOW at wwwiainsidercouk
Published by Spitzer and Boyes LLC Write in 15 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
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Frost says the push from developing
economies is important as the market
is technologically mature and seeing
restricted growth in developed econo-
mies This is particularly true in Europe
and North America where recent finan-
cial insta-
bility has
reduced capital expenditure across end-
user industries
Bill Moore senior vice president of
sales development and channel man-
agement for global bearings manufac-
turer SKF says ldquosmartrdquo products and
the expansion of robust reliability pro-
grams are helping to drive new invest-
ment particularly in developed coun-
tries where the cost to compete is
high Frost says the magnitude of
the existing global installed base will
strengthen the need for replacement
and upgrades adding to market de-
mand as well
Frost says despite the potential
in developing economies the focus
on price as a product differentiator
may lead to intense price pressures
among manufacturers and bring down
the value of the overall market in the
short term The growing trend among
consumers to choose low-cost Chinese
imports will complicate this challenge
As price and quality become stan-
dardized across the globe customers
will base more of their purchasing deci-
sions on value-added services accord-
ing to Frost This will push manufactur-
ers to create more maintenance-free
solutions such as lubrication-free
bearings that offer end-users savings
on service and replacement costs and
reduce downtimeldquoOffering a complete line of prod-
ucts with comprehensive services will
be another feather in the cap of ven-
dors looking to widen their consumer
baserdquo notes Frost Industrial Automa-
tion and Process Control Research
Analyst Guru Mahesh
Moore says the trend of outsourcing
manufacturing to regions where labor
and production costs are favorable is
becoming less of a factor
ldquoThe days when cheap labor made
a significant difference in where a prod-
uct is manufactured mdash particularly high
value-added products or high weight
and bulk products mdash are coming to
an end as the cost of transportation
storage and inventory balance out the
benefits of production costs where la-
bor is a smaller percentage of the cost
of manufacturingrdquo Moore says ldquoLocal
manufacturing development will indeed
come to developing countries as their
ability to create markets that generate
economies of scale that support local
production is a clear trend and one that
all manufacturers will pay attention tordquo
Moore says that development of
maintenance-free or predictive tech-
nologies and products will be a sig-
nificant advantage to everyone in the
Bearing amp Coupling Manufacturers Focus
onDEVELOPING Economies
amp EFFICIENCY InnovationBy Amy W Richardson
2 January 2015
Flow Control Magazine
|
gy
Anew study from Frost amp Sullivan (wwwfrostcom) fore-
casts steady growth for the overall bearings and couplings
market based on rapid industrial development in high-growth
regions Specifically Frost predicts development in Mexico
Indonesia Nigeria Turkey Brazil Russia India and Chinawill help boost the bearings amp couplings market from $2206
billion in 2013 to an estimated $2676 billion in 2018
The development of maintenance-freeor predictive technologies will helpboost growth in the bearings market For example SKF is developing products that will automatically notifyusers when a bearing or mechanicalrotating component is approachingthe end of its useful life Pictured hereis an SKF Microlog analyzer a por- table condition monitoring tool
COURTESY SKF
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
improved productivity through simplified solutions The powerful technology and tools ensure repeatable
reliable accurate measurements Easier access to process data allows for better troubleshooting process
optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
For daily product notes visit the lsquoFeatured Productsrsquo section flowcontrolnetworkcom
ON THE WEB
1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3845
FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
and benefits as well as grids of
instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
services provided for the
mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
Brought to you by Beamex
Your Source For Fluid Handling Videos
Go towwwflowcontrolnetworkcomfreeinfo
Select appropriate issue ofFlow Control Magazine
Select advertisements thatinterest you
Enter your email amp clickldquoSubmit Requestrdquo
1
2
3
4
PRODUCT
INFORMATION
ONLINE
Follow these 4 steps to receive freeproduct information from suppliers
FREE
FEATURED VIDEO How to Calibrate aPressure Measurement Loop
For more information about FlowTube
sponsor packs email FlowControlGrandViewMediacom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4245
THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
Name ________________________________________________________________
Title _________________________________________________________________
Company _____________________________________________________________
AddressCityStateZip __________________________________________________
______________________________________________________________________
Phone ________________________________________________________________
E-Mail ________________________________________________________________
One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545
![Page 9: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/9.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 945
20 Years of Flow Control This
year marks the 20th Anniversary of
Flow Control magazine Launched
in 1995 with the aim of serving technical
professionals involved with designing oper-
ating and maintaining fluid handling systems in a wide range of
industries Flow Control has leveraged its many years of experi-
ence to establish a unique niche and reputation for providinghigh-quality information to you our subscribers I congratulate everybody who helped
Flow Control get to where it stands today Herersquos to another 20 years of success
Training Time Itrsquos a new year and we have two new
training opportunities for
you to enhance your skillset in 2015
Regular Flow Control columnists Da-
vid W Spitzer and Larry Bachus will
be presenting three-day courses on
Flow Measurement and Pumping
Systems respectively I encourage you and your colleagues to take ad-
vantage of these important training
opportunities For more details see
flwctrlcomflowseminar amp
flwctrlcompumpguy
Oil amp Gas Gender Gap Results of a
new global workforce survey conduct-
ed by OilCareerscom and Air Energi
show a gender gap in the oil amp gas industry
persists despite ongoing efforts to recruit more
women into the industry According to hiring
managers the
top three factors
that significantlycontributed to
the gender gap
in the oil amp gas
industry are
1 A lack of women entering the industry (55
percent)
2 An industry culture created by a male-domi-nated environment (53 percent)
3 The logistics requirement ie travel shift
and working patterns in the field (30 percent)
For more on this story and an infographic seeflwctrlcomog_gendergap
Rockwell Automation Fair 2014 Our colleagueKevin Parker at Processing magazine attended the
annual Rockwell Automation Fair Nov 9-10 in
Anaheim Calif Parker gleaned some interesting perspec-
tive on key trends in process automation including
1 Hardware and software are more blended than ever
2 Fog computing (a kind of cloud computing) is making
headway in industrial engineering environments where latency is a critical concern
For Parkerrsquos full report from the Automation Fair see flwctrlcomrockwellfair2014
DITORrsquoS FILE
6 | January 2015
Flow Control Magazine
4 Flow Things You Need to Know
GROUP PUBLISHERPROCESSINGFLOW CONTROL
MICHAEL C CHRISTIAN | (908) 507-5472mikecgrandviewmediacom
NATIONAL ACCOUNTS MANAGERJIM SEMPLE | (908) 963-3008 jsemplegrandviewmediacom
EXECUTIVE DIRECTOR OF CONTENTMATT MIGLIORE | (610) 828-1711
mattgrandviewmediacom
MANAGING EDITOR AMY W RICHARDSON | (205) 408-5050
arichardsongrandviewmediacom
COLUMNISTS
LARRY BACHUSDAVID W SPITZER JESSE YODER
ART DIRECTORJULIE FLYNN
juliegrandviewmediacom
MANAGER - DIGITAL OPERATIONSMARY BETH ROMANO
SUBSCRIPTION amp REPRINT REQUESTSflowcontrolhalldatacom
Administrative TeamGENERAL MANAGER
BARRY LOVETTE
CHIEF OPERATIONS OFFICERBRENT KIZZIRE
VICE PRESIDENT OF FINANCEBRAD YOUNGBLOOD
VICE PRESSIDENT OF B2B GROUPMIKE WASSON
CHIEF REVENUE OFFICERCHRIS DOLAN
VP AUDIENCE DEVELOPMENTDELICIA POOLE
AUDIENCE DEVELOPMENT MANAGER ANNA HICKS
DIGITAL AUDIENCEDEVELOPMENT ANALYST
STACY BARNES
EDITORIAL ADVISORY BOARDLarry Bachus Bachus Company IncGary Cornell Blacoh Fluid Control
Jeff Jennings Equilibar LLCMitch Johnson JMS SoutheastPeter Kucmas Elster Instromet
Jim Lauria Water Technology Executive
John Merrill PE EagleBurgmann IndustriesSteve Milford Endress+Hauser US Tom OrsquoBanion Emerson Process
Management Micro MotionDavid W Spitzer PE Spitzer and Boyes LLC
Tom Tschanz McIlvaine Company John C Tverberg Metals and Materials
Consulting EngineersJesse Yoder PhD Flow Research Inc
WINNER
WINNER WINNER
PERSPECTIVES FROM THE MONTH THAT WAS IN THE WORLD OF FLOW CONTROL
WINNER WINNER
THE
NETWORK
1
2 3
4
1 9 9 5 - 2 0
1 51 9 9 5
- 2 0 1 5
20th20th
Matt Migliore Executive Director of Content MattGrandViewMediacom
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1045
Endress+Hauser Inc
2350 Endress Place
Greenwood IN 46143
infousendresscom
ww wusendresscom
Sales 888-ENDRESS
Service 800-642-8737
Fax 317-535-8498
Guided wave radar level products - built for safety precision and efficiency
bull Reliable non-contact measurement even for changing process conditions
bull HistoROMreg data management - concept for fast and easy
commissioning maintenance and diagnostics
bull Multi-Echo Tracking evaluation - highest reliability even with the
presence of obstructions in the vessel
bull Hardware and software developed according to IEC61508 up to SIL3(in homogeneous redundancy)
bull Seamless integration into control or asset management systems
bull Worldrsquos easiest proof test concept for SIL saves time and cost
wwwusendresscommicropilot-radar-level
The newest generation of Micropilot
Taking your process to the next level
Write in 7 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1145
HE OUTLOOK | News amp Notes
1 ISO15848 ldquoMeasurement test and qualification proce-
dures for fugitive emissionsrdquo
a Part I ndash ldquoClassification system and qualification proce-dures for type testing of valvesrdquo
b Part II ndash ldquoProduction acceptance test of valvesrdquo
2 API 622 ldquoType Testing of Process Valve Packing for Fugitive
Emissionsrdquo
3 End-user defined fugitive emission reduction requirements
Key aspects of valve testing per API 624 include
The standard covers rising and rising-rotating stem
valves up to 24rdquo diameter
Class 1500 valves are not covered
The test medium is methane
310 test cycles are required with three thermal cycles Temperature application range is from -29 C to 538 C
with last cycle 10 cycles user-defined (can be -45 C)
Re-tightening of gland bolts is not permitted during test
Valve stem test orientation is vertical
Several valves must be tested to achieve API 624 com-
pliance Similar industry principles applied to test valves
qualify two nominal sizes smaller one size larger and one
pressure class below
Allowable leakage is 100 PPM maximum
Gate and globe valves need to be tested separately
For example Gate Valves per API602 four tests API600
eight tests (up to 20rdquo diameter) API 603 eight tests andfor Globe Valves per API 602 four tests
Test valves should be production valves not specially
manufactured test valves
As a result of the release of API 624 testing companies have
been gearing up for an increase in the number and size of
test valves and new test houses are coming to market Withthis in mind implementation of API 624 needs to be carefully
monitored and claims from valve manufacturers should be
validated by requesting to view test results Important factors
to be mindful of include
Number of cycles on some valves could be detrimental
to packing as certain smaller size valves donrsquot come with
grease ports to keep the stem lubricated all of the time
Test failures of valve stem threads yokes and glands
Grease traps into packing and causes leakage
At higher temperatures a few greases create volatile
organic compound and burn off
Testing in vertical generates more heat in yoke area
Certain challenges need a good testing company that has
experience in testing on fugitive emissions and provides
guidelines to manufacturers in terms of use of packing valve
grease testing requirements etc
A preliminary survey was conducted with end-users regard-
ing current utilization and application of API 624 For a sum-
mary of responses from this survey visit flwctrlcom1oWijWz
Gobind Khiani PEng is with Fluor Canada Ltd Khiani has
spent 20-plus years in the energy and power business and 10-
plus years in the Western Canadian oil and gas industry Hecan be reached at 403 850-6982 or gobindkhianifluorcom
Valve Standards UpdateEnd-users ramp up compliance efforts for API 624
as new specifications emerge on the horizon
8 | January 2015
Flow Control Magazine
By Gobind Khiani
In the May 2014 issue of Flow Control (page
16) the new standard API 624 ldquoType Testing
of Rising Stem Valves Equipped with Graphite
Packing for Fugitive Emissions First Editionrdquo was
addressed This standard which was published
and put into effect in February 2014 estab-
lishes guidelines for testing industrial valves for
emissions compliance Since the publication ofthe May article further requests from industry
have spurred the creation of another specifi-
cation API 641 ldquoType Testing of Quarter-Turn
Valvesrdquo and an API ldquoPiping and Valvesrdquo commit-
tee has been formed Regulators and end-users
are also working on
1992 1998 2003 2008 2013 2020
4
35
3
25
2
15
1
05
0
M i l l i o n o f
t o n n e s y e a r Will API 624
have a stepeffect in reducing
fugitiveemissions
Global valve fugitive emissions
End User response at best
End User response actual
S O U R C E G O B I N D K
H I A N I
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1245
Intelligent Features to Boost Global WaterDesalination Pumps Market
The Global Water Desalination
Pumps Market is expected to grow
at a CAGR of 77 percent from 2015 to
2019 according to a new report from
TechNavio (wwwtechnaviocom)
The report shows demand for water
treatment has increased significantly in
developing countries where fresh wa-
ter resources can be scarce Providing
clean and potable water to huge popu-
lations has become a priority which is
pushing the demand for water desalina-tion pumps in the market according to
TechNavio
The report emphasizes the emer-
gence of intelligent pump systems as
a major driver of market growth In-
telligent pumps possess the ability to
regulate flow and pressure and these
systems can automatically adjust to
process and pump system changes
ldquoIntelligent pump systems are be-
ing adopted by many manufacturers
because of the high level of fault toler-
ance ability which leads to a significant
reduction in the total cost of owner-
shiprdquo said Faisal Ghaus vice president
of TechNavio in a news release ldquoThe
adoption of these systems will also
help industries comply with current Eu-
ropean Union regulations in relation toreduction in energy consumptionrdquo
The growing demand for clean wa-
ter worldwide will continue to augment
the demand for water desalination sys-
tems which will propel the Global Water
Desalination Pumps Market during the
forecast period
trendlines
wwwflowcontrolnetworkcom January 2015 | 9
Write in 8 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
Intelligent pump sys-tems are being adopt-
ed by many manufac-
turers because of the
high level of fault tol-
erance ability which
leads to a significant
reduction in the total
cost of ownership
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1345
HE OUTLOOK | News amp Notes
10 | January 2015
Flow Control Magazine
Hydraulic Fracturing WaterTreatment amp Reuse Expected to Soar
Wastewater treatment spending for
hydraulic fracturing is expected to
grow almost three-fold from $138 mil-
lion in 2014 to $357 million in 2020 in
the US according to a new report from
Bluefield Research
The US hydraulic fracturing industry
consumes over 1 billion barrels of wa-
ter annually producing 450ndash500 mil-
lion barrels of contaminated water for
disposal with only about 14 percent
treated and reused Bluefield cites watersupplies increasingly at risk tighter regu-
lations emerging in key states and costs
of disposal on the rise as factors con-
tributing to the substantial rise in water
treatment and reuse which is expected
to account for 27 percent of total pro-
duced and flowback water by 2020
Overall the US hydraulic fracturing
industry will spend $638 billion in 2014
on water management Water transport
and disposal costs will account for 66
percent of the total water managementspent this year with treatment compris-
ing roughly 2 percent
Bluefield reports water scarcity in
Western US states has had little im-
pact to date on fracturing water supply
but that is likely to change if droughts
persist Meanwhile state regulators are
beginning to tighten control of produced
water disposal In Pennsylvania where
policymakers in 2010 placed discharge
limits on wastewater from unconven-
tional oil amp gas operations statewide
treatment and reuse rates for the Mar-
cellus jumped to 90 percent in 2014
The increasing cost of transport and
injecting water into wells mdash now ac-
counting for 66 percent of water servicesspending mdash and the improving cost
structures of treatment provide another
driver of reuse Bluefield reports Well
operators that employ treatment and re-
use solutions spend on average $880
per barrel of water used compared to
$1020 per barrel of water trucked and
injected into wells although cost com-
parisons are site specific
ldquoFracking has been the Wild West for
the US water industryrdquo said Reese Tis-
dale president of Bluefield Research ina prepared statement ldquoThere are three
reasons for this first there has been
an explosive build-out of fracking well
installations now surpassing 126000
Second there has been a lack of clear
regulation on water management in key
markets And third there is not a one-
size-fits-all treatment solution for frack-
ing meaning solutions providers have
had to ascend a steep learning curve
to treat the variable wastewaters that a
single well is capable of producingrdquo
Tisdale notes that these inhibitors
while still acute are beginning to take on
a new form This is partially due to signifi-
cant gains in water management experi-
ence realized adoption of more efficientwater management strategies among
well operators and the emergence of
new policy mechanisms from regulators
that are playing catch-up with the fast-
moving hydraulic fracturing industry
trendlines
Treatment2
Disposal
6
Supply10
Storage22
Transport60
US $638Billion
S O U R C E B L U E F I E L D R
E S E A R C H
Write in 23 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
Industry-Leading
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bull Probe type industrial RTDsbull Electronic temperature switchtransmitter bull Vapor-actuated remote thermometersbull Digital temperature indicatorsbull Platinum resistance temperature transmitterbull Compact OEM temperature transmitter bull Industrial amp instrument type bimetal thermometersbull Thermowells
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1445
New Technique Could ReduceEnergy Required for Oil Refinement
UK scientists have developed a
technique they say has the poten-
tial to dramatically reduce the amount
of energy required for the refinement
of crude oil
Professor Martin Schroumlder and Dr
Sihai Yang from The University of Not-
tingham (wwwnottinghamacuk ) have
led a multi-disciplinary team of scien-
tists from Nottingham the Science and
Technology Facilities Councilrsquos (STFC)
ISIS Neutron Facility Oak Ridge Na-tional Laboratory and Diamond Light
Source to discover a porous material
that works like a chemical sponge to
separate a number of important gases
from mixtures generated during crude
oil refinement
According to a news release from
The University of Nottingham the ex-
isting industrial process uses ldquohuge
amounts of energy to separate and pu-
rify these gases so the new technique
has the potential to revolutionize the oil
industry by significantly reducing car-
bon emissions and making the process
more environmentally friendlyrdquo
Commercially UsefulCrude oil is a raw material that is
refined to produce fuel for cars toheat homes and to create polymers
and other useful materials It is made
up of a complex mixture of hydro-
carbons (chemical compounds that
contain only hydrogen and carbon) of
which certain components are espe-
cially commercially useful
One industrial process used to
achieve hydrocarbon separation is
called ldquocryogenic distillationrdquo which is
widely used worldwide and uses vast
amounts of energy to generate the high
pressures and cryogenic temperatures
required to ensure efficient separation
research amp development
wwwflowcontrolnetworkcom January 2015 | 11
PLASTIC CONTROL VALVES FORALL YOUR CORROSIVE APPLICATIONS
PO Box 938 bull Angleton TX 77516Tel (979) 849-8266 bull wwwcollinsinstcom
Collins plastic control valves are
highly responsive control valves
designed for use with corrosive
media andor corrosive atmos-
pheres
Collins valves feature all-plastic
construction with bodies in PVDF
PP PVC and Halar in various body
styles from 12 - 2 with Globe
Angle or Corner configurations and
many trim sizes and materials
Valves may be furnished without
positioner for ON-OFF applications
Call for more information on our
plastic control valves
Write in 9 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1545
of hydrocarbon mixtures into pure components
However researchers say an innovative solution may
have come in the form of a novel chemical sponge This
porous material a metal-organic framework was devel-
oped by the same team at Nottingham just two years ago
Now in research published in Nature Chemistry for the
first time scientists have proven that it can be used toseparate hydrocarbon mixtures without the need for high
process pressures or very low process temperatures
Reusable MaterialsMade from cheap organic materials aluminum nitrate
salt and water the porous material called NOTT-300 is
able to adsorb different gases found in mixtures of hydro-
carbons at different rates making it possible to sepa-
rate them and extract the most useful ones NOTT-300
requires less energy to function than existing methods
as it operates at ambient temperatures and normal pres-
sures researchers say The gases that are adsorbed intoNOTT-300 can be removed without a significant energy
input and therefore the material can be easily reused
The team of scientists from Nottingham used Diamond
the UKrsquos synchrotron science facility as well as STFCrsquos
ISIS Neutron Facility and Oak Ridge National Laboratory
the UKrsquos and USArsquos world-leading neutron facilities re-
spectively to prove that the sponge works under real-life
conditions
Professor Martin Schroumlder Dean of the Faculty of Sci-
ence at Nottingham said in the news release ldquoIt is a very
important to be able to separate different hydrocarbons ef-
fectively and efficiently with low-energy consumption Po-rous solids such as the metal-organic framework system
studied here represent important materials for the future
development of low-energy separation technologies We
are most grateful to our collaborators at ISIS Neutron Fa-
cility Oak Ridge National Laboratory and Diamond Light
Source in bringing this work to fruitionrdquo
Significant Impact on Oil IndustryDr Sihai Yang the winner of Diamond Young Scientist
and BTM Willis Prize is a Senior Research Fellow at
Nottingham He led the project together with Professor
Martin Schroumlder Yang said ldquoWith the help of advancedcentral facilities like Diamond ISIS and ORNL we have
developed a new separation technique which can poten-
tially reduce the energy usage associated with oil petro-
leum and chemical industries which require the separa-
tion of raw hydrocarbons from crude oil
The discovery of the new material NOTT-300 could
have a significant impact on the oil industry by removing
the necessity for some energy-intensive refinement pro-
cesses researchers say
The research was funded by Engineering and Physical
Sciences Research Council (EPSRC) the European Re-
search Council (ERC) The University of Nottingham andLeverhulme Trust
12 | January 2015
Flow Control Magazine
Write in 21 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
No media contact - No risk of leaks
No process Shut-Downs for installation
No bypass needed
For hazardous area locations (FM approved)
Monitor your Total Acid Consumption
Increase your Plant Up-Time
Balance your Processes
PIOXreg S
PIOXreg S - the evolution of flow and concen-
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Non-intrusive mass flow concen-
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of aggressive media
wwwpiox-scom
wwwfleximcom
Contact us for a free trial measurement
Thank you for your votes and
making PIOXreg S a Flow Control
Awards Winner
THE OUTLOOK | News amp Notes
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1645
The ASCO trademark is registered in the US and other countries The Emerson logo is a trademark and service mark of Emerson Electric Co copy 2014 ASCO Valve Inc
1-800-972-ASCO (2726) | e-mail info-valveascocom | wwwascovalvecomSpoolValve
Now get spool valves with industry-leading ASCO solenoid technology built in
Delivering unmatched performance and durability our compact new valves are
perfect fits for all your onshore near-shore or offshore upstream control panels A
range of easily configured features and options includes superior temperature and
pressure ratings plus low-power models The industryrsquos toughest testing ensures
every rugged stainless steel valve meets or exceeds specifications Plus we design
and support every spool valve we make Ask for ASCO the ultra-reliable choice for oil
and gas control panels
These new spool valves will fit right in
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 174514 | January 2015 Flow Control Magazine
PPLICATIONS CORNER | Process Instrumentation
This is the final article in a series based on the troubleshoot-
ing of a mysterious unit shutdown due to flowmeter perfor-
mance problems
If yoursquove followed this column for most of 2014 you know
that what should have been a liquid ammonia stream to the
feed plant became problematic due to the occurrence of
bubbles of ammonia gas These bubbles caused an ultrasonic
flowmeter in a unit to indicate zero flow and caused the reactor
to scram (shut down) under warm operating conditions The source of the bubbles was traced back to the pres-
sure drop associated with a control valve located at the
exit of the liquid ammonia tank farm
This issue was resolved by identifying the problem
and fixing it at its source This was a pragmatic ap-
proach at the time (early 1980s) given the operation
of the cooling system in the unit and the limited selec-
tion of applicable flowmeter technologies
By the early 1990s changes were implemented that elim-
inated all process cooling requirementsmdashexcept for the small
jacketed cooler upstream of the liquid ammonia flowmeter In
other words after these changes the entire cooling system
would be operated and maintained to cool a few meters of
one small ammonia pipe Coincidently at about the same
time Coriolis mass flowmeters became more mature and
could reasonably measure the mass flow of liquid streams
with homogeneous low levels of vapor
The convergence of these two events resulted in another
approach to the problem that was not available in the early
1980smdashie install a Coriolis flowmeter that could operate in
the presence of bubbles The purchase and installation of a
Coriolis mass flowmeter was given high priority given its im-pact on unit operation economics and safety (by eliminating
the ldquomidget-makerrdquo (see March 2014 page 14))
Plant requirements and the technology that can meet
plant needs keep changing An excellent solution today can
become outdated in just a few years However there are few
substitutes for understanding fundamentals when addressing
a problem In other words there can be more than one way
to skin a cat FC
wwwspitzerandboyescom
Problem Solved AgainA Coriolis mass flowmeter provides a better solution
F o r B e t t e r P i p i ng S y s t e m P e r f o r m a nc e hellipFor Better Piping System Performancehellip
I d e a l f o r Ag g r e s s i v e C h e m i c a l s
1384 POMPTON AVENUE CEDAR GROVE NEW JERSEY 07009
973-256-3000 bull Fax 973-256-4745www p l as t om a t ic co m bull i n f o p la s t om a t ic co m
bull Rugged thermoplasticshandle corrosive andultra-pure chemicaltreatments
bull Constant pressure enhances
pump performancebull Prevents overpressure in
piping system
bull Wide range of pressuresettings
bull PTFE shaft and diaphragm designs
bull 1 4rdquo - 3rdquo sizes in PVC CPVC PVDFPolypro and PTFE
bull First State approved
thermoplastic valve for
anti-siphon applications
Write in 10 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
David W Spitzer
Ammonia Gas | Coriolis Flowmeter | David W Spitzer | Scram | Troubleshooting
FLOWSTREAM Find related content flowcontrolnetworkcom
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and Boyes
LLC offering engineering seminars strategic marketingconsulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer can be reached at 845 623-
1830 or at wwwspitzerandboyescom
The purchase and installation of a
Coriolis mass flowmeter was given
high priority given its impact on unit
operation economics and safetyldquordquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1845
Smart Valve Positioner
Beyond Control The NEW Research Controlreg SRD positioner does
everything you expect any valve positioner to do
plus more The SRDrsquos comprehensive diagnostics tool
continuously monitors for fugitive emissions delivers
real-time performance statistics and facilitates both
proactive and reactive process management Available
with integrated network communications the SRD is
compatible with Research Control valves and most other
pneumatically-actuated valves
Visit wwwbadgermetercomSmart-Valve-Positioners or
call 877-243-1010 for more information today
copy 2015 Badger Meter Inc
RESEARCH CONTROL is a registered trademark of Badger Meter Inc
Write in 11 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1945
Process improvements to increase yield or cut manufactur-
ing costs typically require enhanced process control but the
installed base of measurement instrumentation in a process
plant may simply be unable to facilitate improvements because
of age inadequate performance or unreliability Maintenance
cost and unscheduled process downtime for an aging process
plant can be very damaging to the balance sheet Upgrading
to new more accurate and more reliable instrumentation can
be prohibitively expensive New plant construction must alsomaintain a focus on optimizing costs for the process control
infrastructure The budget approval decision for new plant
construction must weigh such costs against projected market
conditions for the products that the plant is intended to manu-facture In todayrsquos volatile global marketplace return on invest-
ment calculations for plant upgrade or new plant construction
projects may go through several iterations before the trigger is
finally pulled or indeed not pulled
This article describes advances in two-wire instrumenta-
tion specifically in relation to flowmeters that have taken
place in the past few years and the significant cost benefits
that this new technology can realize for plant builders and op-
erators in terms of capital investment and cost of ownership
The Significance of Two-Wire Loop Power
A survey involving 204 participants in the chemical indus-try across Germany Switzerland the UK Canada and the
United States (Manfred Koenig PhD KIM Ludwigshafen
Germany 2006) revealed an 87 percent preference for two-
wire instrumentation versus four-wire in process applications
and 89 percent for utilities This overwhelming preference
may stem from the fact that older process plants were built
with two-wire twisted-pair cable networks connecting all
process units and measuring instruments together in an
overall plant control scheme
However these existing cables are relatively unsophisti-
cated and incapable of supporting anything but low-energy
instrumentation that is insensitive to interference from otherelectrical sources that might be sharing the same cable con-
duit Further the low energy levels supported by these two-
wire loops are more easily rendered safe in terms of explo-
sive risk in hazardous areas containing flammable materials
Many older process plants are also likely to have a significant
installed base of flowmeters employing pre-war (pre-1945)
technology such as positive displacement (PD) turbine vari-
able area (VA or Rotameter) and differential pressure (dP)
Market data firm Flow Research Inc (wwwflowresearch
com) indicates collectively a future compound negative annual
growth rate approaching minus 3 percent to 5 percent for PD
turbine and VA flowmeter types while dP is expected to keeppace with market growth (World Market for Flowmeters 2010)
YSTEMS DESIGN | Flow Measurement
16 | January 2015
Flow Control Magazine
The Two-Wire
ADVANTAGENew wiring options enable modern instrumentsto drive cost savings in existing plant systems
By Steve Milford
Advances in two-wire instrumentation have enabled mod- ern technology to be employed to the advantage of older
plant and process systems
Some chemical manufacturing plants are
competing for survival not only externally
against other global companies but also
internally among the global facilities of theirown company Other industry sectors face
similar challenges
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2045wwwflowcontrolnetworkcom January 2015 | 17
The Need to Replace Older TechnologiesUntil the 21st century two-wire loops were only able
to support these relatively unsophisticated instruments
which convert their measurement by various means into a
4-20mA output or pulse signal to the control system The
more advanced post-war flowmeter technologies such as
Coriolis ultrasonic or electromagnetic flowmeters have
until just eight years ago required a dedicated power sup-
ply for their function in addition to the output loop and
thus a four-wire infrastructure was required as a minimum
Therefore upgrading older two-wire meter devices to moremodern four-wire technology could require significant
expenditure in terms of the installation of separate power
cables and supply modules
There was a major breakthrough in 2006 when a true
two-wire loop-powered inline liquid ultrasonic flowmeter
was introduced (Figure 1) The nature of this breakthrough
was innovation in device power management This was the
missing piece up to that point because to be a true loop-
powered device the meter had to directly provide a full 16
mA span using less than 36 mA of remaining loop current
and less than 1 Watt of electrical energy The flowmeter
operated on a single 4-20 mA HART two-wire loop wasremotely powered by a DC supply was certified Class 1 Divi-
sion 1 and could be deployed as Intrinsically Safe through
the use of an approved safety barrier
A true two-wire loop-powered Coriolis flowmeter followed
in 2011 (Figure 2) employing a new and more advanced
common electronics platform A two-wire loop-powered inline
ultrasonic flowmeter for low-pressure gas was introduced in
2012 and a second two-wire loop-powered Coriolis meter fol-
lowed in 2013 offering improved measurement performance
and an additional high-performance meter tube material
Electromagnetic and vortex flowmeters had already been
available for some years in two-wire loop-powered form butimproved performance resulted as these designs were incor-
COURTESYENDRESS+HAUSER
Figure 1 A two-wire ultrasonic flow- meter released in 2006 operated ona single 4-20 mA two-wire loop
Write in 12 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
omegacom
reg
I I I I LL I
I I I I LL I
copy COPYRIGHT 2015 OMEGA ENGINEERING INC ALL RIGHTS RESERVED
1-888-826-6342
Prices listed are those in effect at the time of publication and are subject to change without noticePlease contact OMEGArsquos sales department for current prices
FPD3000 SeriesStarts at$630
FPD3300 SeriesStarts at
$790
Visit omegacomfpd3000
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OSXL-TIM3$999
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Positive Displacement Flow Meterfor Fuels and Oils
bull Aluminum Bodybull FKM Sealsbull Temperatures up to
80ordmC (176ordmF)bull NPT or BSP Threadsbull DIN JIS or ANSI
Connection (Availableon 1 and Larger Sizes)
Positive DisplacementFlow Meter for Solvents
Thermal Imaging CameraFor Inspection andFactory Diagnosis
Note Not for ExportUSA Only
Your One-StopSource for Process
Measurement and Control
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 214518 | January 2015
Flow Control Magazine
porated into their new common electron-
ics platform in 2013 So all the ldquomodernrdquo
flow measurement technologies mdash that
is to say those introduced post-war mdash
have become available as two-wire loop-
powered devices with one exception
namely thermal mass (thermal disper-
sion) meters Unfortunately the power
requirements for this technology exceed
what is currently deemed possible withtwo-wire loop-power management
Payback forTechnology UpgradeConsider a 1rdquo process line
containing a liquid process
ingredient costing $1lb at a
mass flowrate of 150 lbmin-
ute We have $150minute
flowing in the line translating
to $9000hour and $72000
per eight-hour shift That cal-culates further to $360000
per five-day working week and
for a working year of 40 weeks for
example that is $144 million Assume
the existing device is a turbine flowmeter
Now imagine a two-wire loop-
powered Coriolis mass flowmeter is
installed in place of the existing meter
The line would need to be drained and
probably one process flange replaced
allowing the Coriolis to fit mechanically
in place of the turbine However thetwo-wire loop already used for carrying
the existing meterrsquos flow signal to the
control room can be used unaltered
for the complete electrical installation
aspects of the Coriolis flowmeter
The upside of the change is signifi-
cant and clear cut Assuming the exist-
ing meter measurement uncertainty was02 percent of reading then measure-
ment uncertainty improves through use
of Coriolis to 01 percent of reading
giving a 01100 x $14400000 im-
provement in control of the ingredient
annually or $14400 A two-wire Coriolis
mass flowmeter with 01 percent mass
flow accuracy would be paid for in ap-
proximately 6-8 months In practice the
improvement in measurement uncer-
tainty would be greater as the operator
would gain temperature and density in-formation from the Coriolis and the mea-
surement would be devoid of any fluid
property dependence Viscosity change
for example can have a major impact on
turbine meter performance Mechanical
wear and tear that turbine meters even-
tually experience which causes them to
under-register flow is precluded by mod-
ern devices like Coriolis
Furthermore if the process ingredient
was being blended with another then ad-
ditional process improvements could berealized through in-line blending control
using Coriolis technology for final density
as the control point It is possible to have
dual 4-20 mA outputs from two-wire
loop-powered meters but as the main
4-20 mA output representing the prima-
ry variable is also HART then an external
HART Loop Converter or HART IO card in
the control system can provide second-
ary tertiary and quaternary variables as
4-20 mA signals A Coriolis meter is trulya multi-variable device Certain two-wire
devices are also available with Profibus
or Foundation Fieldbus communication
Cutting Wiring CostsIn 2003 WIBEXERA (International
Instrument Usersrsquo Associations) Report
T 2732 X 03 was published and it pro- vided an average survey of prices quoted
in projects at that time for the provision
of power supplies for four-wire instru-
ments The price ranged from euro1200
to euro1800 per instrument depending
upon design and plant characteristics
for an average cost of euro1500 (about
$2000) It would be reasonable to
assume an inflationary factor of 2 per-
cent per annum giving an approximate
current-day figure of $2500
From another source within thechemical industry an estimation of
$40foot to $50foot was given for in-
stallation of four-wire cabling For a
linear 50-foot cable run with for ex-
ample a 10-foot vertical at each end
this equates to $3150 Actual costs
and budget estimates have been given
as high as $10000
The Extent of the Opportunity The modern post-war flow measure-
ment technologies have different powerrequirements and consequently they
are not all available for the
same size range in two-wire
loop-power form For example
two-wire Coriolis flowmeters
are limited to 2rdquo diameter
electromagnetic and inline
low-pressure gas ultrasonics
are limited to 8rdquo and vortex
and inline liquid ultrasonic are
limited to 12rdquo
Nevertheless for thechemical industry in particu-
lar perhaps two-thirds of the
process pipes in a plant will be no larger
than 2rdquo and even when the host process
pipe is larger a correctly sized flowmeter
can still be less than 2rdquo There is consid-
erable scope for two-wire loop-power to
deliver value for flow measurement ap-
plications with total safety
The virtues of Coriolis technology
have been covered but what about
other two-wire technologies An elec-tromagnetic flowmeter in two-wire form
YSTEMS DESIGN | Flow Measurement
In todayrsquos volatile global mar-
ketplace return on investment
calculations for plant upgrade or
new plant construction projects
may go through several itera-
tions before the trigger is finally
pulled or indeed not pulled
ldquo
rdquo
COURTESYENDRESS+HAUSER
Figure 2 Two-wire Coriolis flowme- ters became available in 2011
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2245
can be used on water wastewater or
a light water-based slurry provided the
fluid has around a 20 microSeimenscenti-
metre (microScm) electrical conductivity
A magnetic flowmeter is full bore un-
less flowrates dictate a reduced meter
size in the interests of performance and
so there are no intrusions into the flow
stream and no pressure loss An accu-
racy of 05 percent of reading is normal
from a two-wire magnetic meter and a
modest five diameters (5D) of straight in-let run is needed to avoid error from up-
stream flow disturbances When the fluid
exhibits insufficient conductivity then
the same performance and installation
requirements can be met by an inline ul-
trasonic flowmeter provided the liquid is
essentially clean and bubble-free
For gas or steam applications a vor-
tex meter is the normal choice Using a
built-in temperature sensor a two-wire
loop-powered vortex meter can calculate
mass flow of saturated steam using in-ternal steam tables An external pressure
input allows mass flow of steam to be ac-
curately calculated even when saturated
steam becomes superheated as can oc-
cur downstream of a pressure regulating
valve With mass flow known the vortex
meter can calculate energy and heat flow
A new and exciting development is
the ability of the vortex meter to indicate
wet steam and calculate dryness frac-
tion or steam quality For safety and ef-
ficiency saturated steam should be dry
and free from condensate that is to say
it should possess a high steam quality
factor However the dry or wet state of
saturated steam can sit on a knife-edge
and shift to the opposing state due to
the slightest change in process condi-
tions Rapid and reliable indication of
this change of state is now available
Perhaps the most astonishingachievement in the power management
of two-wire loop-power flowmeters is
that of the ultrasonic biogas meter It is
now possible not only to measure the
flow of wet dirty variable composition
and low-pressure anaerobic digester
gas landfill gas and coal bed methane
gas with a two-wire loop-powered ultra-
sonic flowmeter but also the same de-
vice uses an inbuilt temperature sensor
in combination with measured sound
velocity to calculate methane contentcalorific value and energy flow
Technology to Take UsForwardModern flow technologies provide instru-
ment engineers with vital self-monitoring
information The format of such infor-
mation is easier to understand and act
upon when presented in accordance
with harmonized international guidelines
for online plant asset management eg
NAMUR Standard 107
Continuous plain-text self-diagnostic
and process-related information with
suggested remedies (Figure 3) make it
possible for instrument engineers andoperators to take action at the appro-
priate time mdash immediately or during
the next scheduled shutdown mdash saving
time and money by knowing the exact
health of their measuring point and the
probable actions required to rectify any
abnormal conditions Device verifica-
tion offering third-party validated trace-
ability can be performed on demand ei-
ther locally or remotely from the control
room without the expense of a man in
the field Calibration is then avoided ordeferred without process interruption
Where a process plant has a large
installed base of older mechanical tech-
nologies the decision to embark upon a
program of replacement for plant mod-
ernization cannot of course be taken
easily There are the stocks of spare
parts to consider along with the plant
instrument technicians who are trained
on and at ease with the old devices
However a process plant that retains
the older technology going forward willbe at risk and may find it increasingly
difficult or even impossible to maintain
a cost position that competes effective-
ly in the global market FC
wwwusendresscom
wwwflowcontrolnetworkcom January 2015 | 19
Steve Milford
is a Flow Product
Business Manager
for Endress+Hauser
Inc in Greenwood
Ind He has been
involved in flow
measurement since
1983 and has been
actively involved with standards devel-
opment for flow technology within the
International Standards Organization
(ISO) and the British Standards
Institute Mr Milford can be reached
at stevemilfordusendresscom
Steve Milford
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Coriolis Flowmeter | Magnetic Flowmeter | Two-Wire | Ultrasonic Flowmeter | Vortex Flowmeter
Figure 3 A modern instrumentrsquos display module can provide continuous plain- text self-diagnostic and process-related information
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2345
The bottom line is the volume of gas under one set of
pressure and temperature conditions is not the same as it
would be for the gas under different conditions Why is thisimportant Without compensation for compressibility read-
ings taken by gas flowmeters can result in measurementsmdash
and costs to the buyermdashsignificantly lower or higher than they
should be
The flow of gas in a system can be accounted for and
reported in a number of ways such as by volume by mass
flowrate and by energy Inline turbine meters can offer both
reliability and accuracy in measuring gas flow when matched
with a monitor capable of calculating and displaying results
that have been adjusted for the nature of the gas and impor-
tantly the pressure and temperature
Measuring Flow with an Inline TurbineFlowmeter
With an inline turbine meter gas flows into the meter through
a length of piping that helps to pre-condition the flow by
reducing undesirable swirls and asymmetry Where consid-
ered necessary a flow straightener may even be installed in
line to create a uniform flow profile to the extent possible
As can be seen in Figure 1 a rotor support within the tur-
bine housing further conditions the flow and directs it through
the blades of the rotor High-precision ball bearings allow the
rotor to freely rotate on the shaft
The rotorrsquos rotational speed is directly proportional to the velocity of the fluid passing through the meter The rotor itself
incorporates magnets (or magnetic blades depending on thedesign) while the housing is non-magnetic
A proximity sensor (also known as a pickup coil) is located
in line with the rotor and detects the electrical pulses gener-
ated by the ferrous rotor spinning through the magnetic field
Each pulse represents a discrete volume of gas The out-
put frequency provides the indication of the gas flow rate and
the accumulated pulses over a specified time represent the
total volume of fluid for that measurement period
Need for Calibration The flowrate of the gas through the meter cannot be deter-
mined accurately unless the meter is calibrated The fac-tory calibration determines the meterrsquos constant known
as a K-factor which is then inputted into the gas monitor
PPLICATION NOTES | Flow Measurement
20 | January 2015
Flow Control Magazine
COMPENSATING for
Compressibility inMeasuring Gas Flow Why K-factor adjustment is essential foraccurate inline turbine flow measurement
Unlike crude oil and other liquid fossilfuels natural gas poses a challenge
in monitoring the quantity of gas flowing
through pipelines While liquids do not com-
press gases do and the mass flowrate of
gas being transmitted through gathering
lines depends on both the pressure and
temperature
By Kevin Clark
Figure 1 Internal components of a liquid turbine flowmeter
C O U R T E S Y
T U R B I N E S
I N C
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2445
Wondering Whether the
Pump Guy Seminar
Is for YouCheck out the ldquoPump Guy Insightsrdquo
video series flwctrlcompginsights
PUMP GUY INSIGHT 1NPSHa vs NPSHrmdashWhy all pumps need gauges
PUMP GUY INSIGHT 3How to Operate Your Pump at Best Efficiency
PUMP GUY INSIGHT 5Head vs Flow
PUMP GUY INSIGHT 2 Your Pumps Are Constantly Moving On Their Curves
PUMP GUY INSIGHT 4 The Role of the Pump Reliability Chain
PUMP GUY INSIGHT 6How to Read a Pump Curve
PARTNER SPONSORSFor more information and to register
for upcoming Pump Guy Seminars
visit FlowControlNetworkcomPumpGuy
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2545
PPLICATION NOTES | Flow Measurement
22 | January 2015
Flow Control Magazine
Gas flowmeters measure the actual volume of gas passing
through the meter per minute irrespective of pressure and
temperature1
The volumetric flowrate of a gas is often corrected to
ldquostandardizedrdquo conditions of pressure and temperature While
ldquostandardrdquo conditions can vary depending on the definition
in the US this typically means a pressure of 1473 PSIA(pounds per square inch absolute) and a temperature of 60 F
The flowrate measurement is reported in standard cubic feet
per minute (SCFM)
Compensating for changes in pressure and temperature is
critical Consider a meter system setup for flowing conditions
of 60 PSIG (pounds per square inch gauge) and 60 F and the
line pressure decreases to 50 PSIG while the temperature
remains constant The difference in SCFM between the two
is more than 15 percent which would cost the buyer more
for the gas than it should As Table 1 demonstrates even a
small variation in pressure will result in a surprisingly high er-
ror percentage
Automation of the K-Factor The K-factor is established by an initial factory calibration In
the case of a non-compensated flow monitor any variations
in pressure and temperature will result in manual adjust-
ments needed to the K-factor In order to maintain accurate
flow measurement users must monitor pressure and temper-
ature and make corresponding adjustments to the K-factor To eliminate these manual adjustments some suppliers offer
a flow monitor that automatically adjusts for any changes in
pressure and temperature
These monitors provide accurate flow measurement regard-
less of changing environmental conditions in some cases sup-
porting applications with pressures as high as 15000 PSIG and
temperatures between -350 F to 350 F with a standard accura-
cy of +-1 percent over a flow range of 05 ACFM to 650 ACFM
Final NotesDuring the operation of a flowmeter system the ability to obtain
a readout mdash and to adjust for line pressure and temperaturechanges mdash is sometimes compromised by a lack of electric
power This issue is especially true along gas pipelines in remote
areas To overcome this limitation some manufacturers have
designed low-powered flow monitors which can operate for up
to on year on a single lithium D-cell battery
It is important for users to recognize the effects of the
compressibility of gas As such the quantity of a gas flow-
ing through a gas flowmeter depends on the pressure and
temperature In order to ensure accuracy any flowmetering
system must employ a means to correct for these effects
Otherwise the readout is certain to be in error and could be
unnecessarily costing money This is particularly crucial onwellhead production and in billing scenarios FC
wwwturbinesincorporatedcom
Notations1 The measurement factor in the US is known as the
ACFM actual cubic feet per minute (Metric units are typically
ACMH actual cubic meters per hour)
Table 1 Error induced by line pressure changes
Constant Temperature with Varying Pressure
Pressure Temperature PulsesSCF Error
50 60 2556027821 1546
51 60 2517123288 1370
52 60 2479385307 1199
53 60 2442762186 1034
54 60 240720524 873
55 60 237266858 717
56 60 2339108911 566
57 60 2306485356 418
58 60 2274759285 275
59 60 2243894166 136
60 60 2213855422 000
61 60 2184610304 132
62 60 2156127771 261
63 60 2128378378 386
64 60 210133418 508
65 60 2074968632 627
66 60 2049256506 743
67 60 2024173807 857
68 60 1999697703 967
69 60 1975806452 1075
70 60 1952479339 1181 Flow Measurement | K-Factor | Measurement
Accuracy | Turbine Flowmeter
Find related content flowcontrolnetworkcomhellipSearch on
FLOWSTREAM
Kevin Clark is senior develop-
ment engineer for Turbines Research
amp Development LLC Turbine RampD is a
subsidiary and the research and techni-
cal support arm of Turbines Inc which
serves a range of industries and applica-
tions from oil amp gas to cryogenic liquids
to custody transferKevin Clark
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2645
Pumps Bearings amp Seals TECHNOLOGY REPORT
FEATURES
SYSTEMS DESIGN
The ComplicatedCase of
Compressors
withSide-Streams
24 28 32BEST PRACTICES
How PumpingSystems
AffectSealing
Performance
TECH OUTLOOK
BearingSuppliers
Drive Gains InDeveloping
Markets
wwwflowcontrolnetworkcom January 2015 | 23
S P E C I AL S E C T I O N
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2745
The design and operation of compressors with side-
streams has always been difficult because flow entering the
compressor needs to be mixed with the core flow already
in the compressor (compressed in section-1) in a manner
that does not degrade the aerodynamic performance of sur-
rounding sections Minimizing losses and ensuring proper
mixing of the side-stream flow and core-flow are required to
ensure effective performance of a compressor of this sort
Key considerations for an application involving compres-
sors with side-stream flow include
The plant process typically dictates the side-stream
flange pressure
The impellers upstream of the side-stream should
achieve the necessary pressure for the core-flow
The side-stream flow is typically at a temperature dif-
ferent from compressor core-flow temperature
Process plants need some degree of operational flex-
ibility ie the ability to support variations in core-flow condi-
tions and side-stream conditions
Modern process plants are usually specifying more than
one operating conditions (sometimes two or more manda-
tory conditions) which can present challenges to compres-
sors with side-streams Adding to these issues modern
compressors should operate with much higher impeller tip
The COMPLICATED CASE ofCompressors with Side-StreamsConsidering key system design requirements
to ensure operational efficiency By Amin Almasi
4 January 2015
Flow Control Magazine
|
y
g
Some compressors in certain applications
have one or more incoming side-streams
(or side-loads) that introduce side-stream
flow to mix with the core flow In other words
a radial side-stream inlet is utilized in multi-
impeller centrifugal compressors to introduce
additional gas into the mid-stage of a com-
pressor This design enables optimization in
some process plants However the flow dis-
tribution after the junction of the side-stream
and the main return channel of the upstream
section can significantly affect the perfor-mance of the next section of compressor
In most cases the pressure levels at these
side-streams should be accurately predicted
to meet the theoretical performance
Compressor station at a natural gas processing plant
R U D M E R Z W E R V E R I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2845
speeds and inlet Mach numbers compared to previous
generations of compressor technology
Likewise side-streams are now com-
monly used with medium-sized and
large-sized compressors (eg 1ndash60
MW) The costs associated with cor-
rections on side-stream compres-
sor applicationsmdashany repair
inefficient operation and power
lossesmdashwould be very high Fur-
ther compressors with side-streams
are usually sensitive and difficult
machines to operate In particular
performance curves (performance
pressures efficiency etc) are sen-
sitive to suction inlet conditionsside-stream inlet conditions vol-
ume flow ratio (side-stream vol-
ume to core-flow volume) and side-stream losses
Compressors with side-stream often perform far below
expectations The main reason is that side-stream compres-
sors are different than conventional compressors (without
a side-stream) in design and operation For a compressor
with side-streams tighter tolerances in operating conditions
must be identified and applied Uncontrolled variations of
suction pressure or side-stream pressure are major prob-
lems Another major issue is the variations of the flow ratio
(side-stream flow to core-flow)
Compressor Side-Stream amp Mixing SectionIn many centrifugal compressors the portion of the side-
stream system from the flange connection to the mixing
section is similar to a compressor inlet A great challenge
is ensuring the mixing section provides circumferentially
uniform merged-flow with minimum losses This can be
achieved via effective design of the inlet configuration and
mixing section of the side-stream compressor such that
the impeller can be maintained over the whole operating
range of the compressor In many cases while there are
mixing sections provided for the machine the flows do not
completely mix before entering the impeller of the section-2
(the impeller after the mixing section) Non-uniformity at
inlet flow to the impeller is a key concern for compressor
performance
Another consideration is a compact design of the side-
stream mixing section Specifically a mixing section with
less axial length is always preferred This axial length can af-
fect the compressor rotor dynam-
ics the rotor length and over-
all compressor performance
(design cost operation and
reliability)
The side-stream exit pressure
(side-stream pressure at inlet
of the mixing section) is mainly
a function of the side-stream
flow velocity and the pres-
sure in the previous section of
the compressor Conversely the side-
stream flange pressure can depend on
side-stream flow velocity and section-1
exit conditions Therefore the side-stream
inlet flange volume flow is a function of theflange pressure compressibility (at that
pressure and temperature) and mass flow
Some engineers assume that the side-stream flange pres-
sure is equal to the inlet pressure of the first impeller of the
section-2 This is not true The mixed total pressure can be
estimated on a mass-averaged basis using side-stream total
pressure and return channel exit (section-1) total pressure
In some designs because of the lower static pressure at
the side-stream exit the total pressure at the return channel
exit is lower even though the velocity upstream is roughly
matched for both streams The pressure usually increased
at the returned channel but it can be reduced again at the
side-stream exit While simple in nature this can have an
impact on the prediction of pressure at the side-stream exit
and overall mixing section performance Based on basic flow
principles it was usually assumed that the static pressure
was equal between both flow streams at the mixing location
While this assumption might be used in rough calculations
the accurate simulations have shown this assumption is not
true In fact there are some points (for instance the shroud
wall at the exit of the return channel and the hub wall at
the exit of the side-stream) where this assumption is true
However this is not valid for all locations There are pressure
changes that occur from a side-stream flange to the inlet
of the next section (section-2) which depend on different
factors The first factor is the frictional losses due to side-
stream geometry from side-stream flange to plenum mix-
ing section etc The other factors are pressure changes due
to local curvature and geometry details of mixing section
Another consideration is the operation of a compressor
with side-stream at part-load The performance of the side-
wwwflowcontrolnetworkcom January 2015 25
Figure 1 An example of a centrifugalcompressor with side-stream
COURTESY SIEMENS
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 29456 January 2015
Flow Control Magazine
|
y
g
stream path the mixing section and
the downstream impellers when ma-
chine is operated at part-load or even
off-design operating flows will result
in additional compressor performance
problems In such a case both veloc-
ity profiles and pressure variations in
various parts (side-stream path mixing
section etc) will be different resulting
in complicated flow patterns and com-
plex aerodynamics behaviors
Side-Stream CompressorSectional Performance
Typically vendor-supplied compressor
performance curves reflect flange-to-flange performance because that is
what the plant engineers need to
evaluate the proper operation of their
system (for example from suction to
side-stream and from side-stream to
discharge) In many cases compres-
sor vendors also provide the over-
all compressor performance curves
and performance curves for section-1
(from suction to side-stream) and sec-
tion-2 (from side-stream to discharge)
Flange-to-flange data if not interpret-
ed properly can lead to false conclu-
sions about the relative performance
of individual sections of a compression
system For example if side-stream
losses from the flange to mixing sec-
tion are attributed to the downstream
section (section-2) it will cause the
downstream section (section-2) to
appear low in performance while the
upstream section (section-1) will show
high performance levels
An important behavior to con-
sider is when the actual side-stream
pressure is different than the rated
side-stream pressure When the side-
stream pressure is slightly higher than
the outlet pressure of the section-1
it (section-1) shows a relatively higher
performance compared to the real sec-
tion-1 performance In some cases
the performance of section-1 could be
considerably higher than section-2 In
other words when performance is de-
termined flange to flange the higher
flange pressure is seen as extra ldquopseu-
dordquo work done by the section (since this
is an inconsistent thermodynamic vol-
ume) resulting in a relatively high sec-
tional efficiency (section-1 shows a rel-
atively high efficiency) This is the case
for many compressors with side-stream
because the whole system is designed
(or specifically the side-stream location
is selected) in a way aimed at main-
taining the real side-stream pressure(side-stream inlet) above the section-1
outlet pressure because if the real side-
stream pressure becomes lower than
the section-1 outlet pressure the flow
may (theoretically) reverse
This is particularly important when
the side-stream mass flow is much
lower than the mass flow of core-flow
The above-mentioned reasons explain
why in many simulations calcula-
tions and performance reports related
to compressors with side-stream the
section-1 shows a relatively good ef-
ficiency and section-2 appears low in
efficiency
When the side-stream pressure is
slightly lower than the outlet pressure
of the section-1 the section-1 might
show a relatively lower performance
compared to section-2 This could oc-
cur in some recycle services where the
side-stream is actually a recycle flow
with a mass flow around two to five
times the core-flow The side-stream
(recycle) flow is returned from down-
stream of the compressor to be slightly
compressed and recycled to the down-
stream Such a recycled side-stream
compressor can present unique chal-
lenges for design and operation This
kind of machine usually needs very
special operating procedures and very
fine adjustments regarding operating
pressures and flows
Side-Stream Compressor
Performance amp Operation An important consideration is the sen-
sitivity of compressor overall perfor-
mance curve and sectional perfor-
mance curves to the flow ratio (ratio
of side-stream flow to core-flow) and
to the inlet conditions Variations in
the flow and pressure of the main
suction and side-stream inlet should
be controlled within tight tolerances
For compressors with side-stream the ASME PTC-10 code stipulates limits on
flow ratio (side-stream volume to core-
flow volume) The acceptable variation
in volume flow ratio in a compressor
with a side-stream is +-5 percent as
per ASME PTC code The requested
side-stream pressure tolerance is not
usually specified in compressor codes
but it should be around +- 2 percent
(or sometimes +- 25 percent)
Variance in flow ratio impacts the
velocity levels where the two streams
merge Significant variation in the ve-
locity profile upstream of the impeller
changes the incidence on the blade
leading edge of the following impel-
ler This change in incidence leads to a
change in sectional performance over-
all compressor performance and train
efficiency
If the flow ratio is varied between 95
percent and 105 percent (tolerances
specified in the ASME PTC-10 code)
the flange pressure changes accord-
ingly resulting in a change in the sec-
tional performance and overall perfor-
mance The sectional efficiency varies
sometimes more than +- 4 percent
This variance reduces as the flow is de-
creased toward surge However as the
flow is increased toward overload the
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3045wwwflowcontrolnetworkcom January 2015 27
variance increases up to higher values
(even in some cases three to five times
compared to variations near the surge
zone) For example in a case study
for a compressor with side-streams a
+- 5 percent variation in flow ratio and
associated changes (pressures losses
etc) the sectional efficiency reduced by
approximately 34 percent at the rated
flow at allowable operating points at
the end of curve (near the overload
ie choke) efficiency reduced by ap-
proximately 55 percent These results
show that the variation in sectional
performance and overall performance
due to flow ratio is highest at operat-ing points near the overload and low-
est at operating points near the surge
For compressors which work most of
the time at high flow (flow higher than
rated flow and discharge pressure low-
er than rated pressure) the effects of
flow ratio deviations (and subsequently
efficiency reduction) would be higher
than compressors working on the left-
hand side of curve (say with sufficient
margins near the surge)
In the compressor codes (such as
API 617) the compressor power varia-
tions should be maintained below 4
percent However in some applica-
tions clients require tighter tolerances
on the consumed power sometimes
below 2 percent (or even below 15
percent) Some studies suggest while
+- 5 percent of volume flow ratio is
suitable for performance test as per
ASME PTC-10 code some plants re-
quire tighter control on the consumed
power and compressor performance
(lower limits on the efficiency) the tol-
erances on the volume flow ratio could
be tighter than ASME PTC code In this
regard +- 4 percent tolerance can be
suggested on the volume flow ratio (ra-
tio of side-stream flow to core-flow) of
compressors with side-streams
Based on operational experiences
acceptable variations in volume flow
ratio and inlet pressures (suction inlet
and side-stream inlet) of a compressor
with side-streams are +- 4 percent
and +- 2 percent respectively
Another important consideration is
the required adjustments for the flow
ratio (side-stream flow to core-flow)
Compressors with side-stream usually
require fixed side-stream flange pres-
sures For a compressor with some variations in operation conditions (even
small changes) it is not usually pos-
sible to achieve optimum operation by
keeping the flow ratio (side-stream to
core-flow) constant The flow ratio has
to be adjusted according to the inlet
flow at which the machine is operating
in order to get the required correspond-
ing side-stream flange pressure
Thermal changes have also been
known to cause some instability in
centrifugal compressors An example is
the thermal-induced change of resid-
ual unbalance For compressors with
side-streams which feature tempera-
ture differences between core-flow and
side-stream flow the thermal behav-
ior of the compressor is usually more
complex and requires more attention
Heavy Gas ChallengeHeavy gases (such as heavy hydrocar-
bon gases eg propane propylene
MTBE (Methyl Tertiary Butyl Ether))
have very low gas sonic velocities that
produce high Mach numbers in the
aerodynamic flow paths For these
services because of high Mach num-
ber high flow coefficient stages have
very narrow flow maps characterized
by limited surge and choke margins
Compressors with side-streams in
these services present great challeng-
es This is to say the side-streams and
associated mixing further complicate
design operation and performance
prediction because the pressure tem-
perature and flow conditions at each
one of these side-streams as well
as at the exit of the machine require
stringent tolerances to optimize the
overall efficiency and performance
As such it is important to accuratelymodel design operate and moni-
tor performance characteristics of any
impellers diffusers return channels
and generally all flow-path components
in a compressor with side-stream FC
Amin Almasi
is a senior rotating
machine consultant
in Australia He is
a chartered profes- sional engineer of
Engineers Australia
(MIEAust CPEng ndash
Mechanical) and
IMechE (CEng MIMechE) holds
bachelorrsquos and masterrsquos degrees
in Mechanical Engineering and is
a registered professional engineer
in Queensland He specializes in
rotating machines including cen-
trifugal screw and reciprocating
compressors gas turbines steamturbines engines pumps subsea
offshore rotating machines LNG
units condition monitoring and reli-
ability Mr Almasi is an active mem-
ber of Engineers Australia IMechE
ASME and SPE He can be reached
at aminalmasiymailcom
Amin Almasi
Compressor | Gas Flow | Performance Curve | Side-Stream Flow
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3145
The pressure in the stuffing box
containing the packing can be estimat-
ed by the following equation
SBP = [Discharge ndash Suction] 3 + Suction
Pressure at the bottom of the stuff-
ing box will be higher than the suction
pressure but considerably lower than
the discharge pressure It should be
noted this calculation will yield a con-
servative estimate of stuffing box pres-
sure that can be further reduced by
pump design
A hole in the stuffing box serves as
a port for injecting clean fluid that cir-
culates around a lantern ring aligned
under the flush port The fluid flushes
solids back into the process to protect
the packing from abrasive wear If the
clean fluid is injected at a pressure ex-
ceeding that at the bottom of the stuff-
ing box some of it will leak back into
the process and some will leak out to
the atmosphere Recommended flush
injection pressure is 15ndash30 PSI (1ndash2
Bar) greater than the pressure at the
bottom of the stuffing box
Fluid injection is also used to lubri-
cate and cool dry-running packing that
is subject to frictional heat and to pre-
vent air from entering the pump which
reduces flow and operating efficiency
Centrifugal pumps utilize three
types of impellersmdashopen semi-open
and closed (Figures 2 3 amp 4) Open
designs prevent fluids with large solids
from clogging the impellers but at theexpense of pump efficiency Backing
plates on semi-open designs serve to
trap the fluid for more efficient opera-
tion Closed impellers are for use with
clean fluids since solids could ac-
cumulate in the eye which would re-
quire tearing down the pump to remove
them
Single-Stage CentrifugalPumpsSingle-stage centrifugal pumps typi-
cally have good bearing support of the
shaft with few run-out or ldquowhiprdquo prob-
lems However in some cases they
are subject to cavitation This occurs
in the eye of the impeller where the
fluid is under vacuum If the pressure
is low enough it will cause the material
to vaporize forming air or water vapor
bubbles As the fluid passes through
How Pumping Systems Design Affects Sealing Performance
By Chris Boss
8 January 2015
Flow Control Magazine
|
Understanding how different types of pump designs impact
sealing is critical to optimizing efficiency safety and lon-
gevity of the sealing system Used for a wide variety of media
including clear fluids solutions and slurries single-stage
centrifugal pumps are one of the most common
types (Figure 1) Fluid drawn into these pumps
enters the eye of an impeller that spins itto the outside of its container
or volute building pressure as
it moves toward discharge
Some of this fluid will work
its way behind the impeller
where it must be sealed with
compression packing or a
mechanical seal
Figure 1
Figure 2 Figure 3 Figure 4
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3245
the pump under increasing pressure
these bubbles implode sending shock
and vibration through the impeller
adversely affecting the seal This phe-
nomenon can be mitigated by running
the pump at slower speed and higher
pressure at the suction end to prevent
air from entering the fluid
Double-Ended Split-CasePumpsOperating on the same centrifugal prin-
ciple but slightly different geometry are
double-ended split-case pumps (Figure
5) Fluid enters both ends of the pump
and is directed into the eye of an impel-ler which spins it out of the volute to
discharge Packing is installed on both
the shaft and bearing ends so the stuff-
ing box is exposed only to suction pres-
sure which is usually quite low
Axial Flow Pumps Axial flow pumps operate like hydro
turbines in reverse whereby a propeller
(or axial impeller) pushes the fluid to
discharge (Figure 6)
Since the stuffing box is located
downstream of the propeller at the dis-
charge end of the pump the packing is
exposed to the full discharge pressure
Vertical PumpsVertical turbine pumps are typically
flange-mounted on a floor extending
downward into a water-filled sump
hole (Figure 7) Available as single- or
multi-stage pumps they feature an
impeller or series of impellers rotated
simultaneously by a single shaft The
impellers increase the pressure of the
upward flow subjecting the stuffing box
to full discharge pressure
Vertical pumps can be quite long so
inadequate bearing support can cause
the shaft to run out This can induce
undesirable lateral motion on the pack-
ing Worse the packing may be forced
to serve both as a bearing and a seal To
withstand these conditions the packing
should be resilient elastic and resistant
to deformation These properties rule
out packing such as graphite foil in favor
of fiber-based materials
Multi-Stage PumpsMulti-stage pumps are used for high-
pressure applications such as feeding
the boilers in steam-powered generating
plants Stuffing box pressure can vary
with pump design and number of stag-
es Designed for clean fluids and high
operating speeds these pumps typically
have high- and low-pressure ends with ahydraulic pressure equalization line run-
ning between the stuffing boxes
Like vertical pumps multi-stage
pumps feature a series of impellers to
build fluid discharge pressure In the
case of the six-stage pump pictured in
Figure 8 fluid enters at the drive end
where a stuffing box is exposed to suc-
tion pressure Channeled from one
impeller to the next through the pump
casting the fluid can reach extremely
high pressures at discharge
A second stuffing box located at the
bearing end is exposed to an intermedi-
ate pressure from the third impeller This
pressure is greater than the suction pres-
sure but much less than the discharge
pressure which can reach 2000 PSI
Fortunately the stuffing boxes in
these pumps are not exposed to dis-
charge pressures and typically see be-
low 500 PSI which is within the range
of some packing materials
wwwflowcontrolnetworkcom January 2015 29
Figure 5
Figure 6
Figure 7
Figure 8
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 33450 January 2015
Flow Control Magazine
| Gear PumpsPositive-displacement or gear pumps
operate on a different principle than
centrifugal pumps In external gear
pumps the fluid flows around the out-
side of the gears the intermeshing
of which forces it through the pump
to discharge (Figure 9) This design
makes these pumps particularly suit-
able for use with highly viscous fluids
such as resins emulsions syrups and
adhesives As such they are used for
transfer or metering applications
It should be noted gear pumps will
continue to displace fluid as long as
their shafts are turning which can pose
a problem if a clog occurs at the dis-
charge The resulting buildup of pres-
sure can blow out seals and damage
the pump Therefore most gear pumps
have pressure relief valves to divert
fluid back to the suction side for re-
circulation through the pump Internal
gear pumps operate slightly differently
but also have pressure relief valves to
prevent damage from excessive pres-
sure (Figure 10) In both external and
internal gear pumps the maximum
stuffing box pressure is determined by
these valves
Other rotating equipment includes
mixersagitators which are similar to
pumps in terms of the speeds to which
the packing is exposed There are ba-
sically three types of mixersagitators
top- bottom- and side-entry Top-entry
models are subject to the same con-
cerns about shaft run-out ldquowhiprdquo and
lateral forces on the paddles that are
encountered in some vertical pumps
Although some fluid may splash onto
the packing these mixers basically run
dry so the packing must have the abil-
ity to dissipate the resulting frictional
heat
In bottom-entry mixers the packing
is always exposed to fluid and may also
be exposed to solids requiring abra-
sion-resistance If the seal fails the en-
tire contents of the tank will eventually
drain out onto the bearings the floor
and other components under the stuff-
ing box
The packing in side-entry mixers may
be fully or intermittently exposed to flu-
id as well as side loading and vibration
Aside from media temperature
speed and other application variables
the configurations and operating prin-
ciples of rotary-type pumps exert differ-
ent forces on the seals used to keep
them from leaking These forces can
spell the difference between accept-
able seal performance and failure
Understanding these differences has
important implications that should be
taken into account to assure proper
sealing selection for long-term trou-
ble-free performance FC
wwwgarlockcom
Chris Boss is
a senior applica-
tions engineer for
Garlock Sealing
Technologies in
Palmyra NY He
has held various
positions in produc-
tion engineering
product development and applica-
tions engineering for the companyrsquos
compression packing division He
is a BSME graduate of the State
University of New York at Buffalo Mr
Boss can be reached at 800 448-
6688 or chrisbossgarlockcom
Chris Boss
Cavitation | Centrifugal Pump | Pump Packing | Sealing System
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Figure 9
Figure 10
Aside from media temperature speed and
other application variables the configurations
and operating principles of rotary-type
pumps exert different forces on the seals used
to keep them from leaking These forces can
spell the difference between acceptable seal
performance and failure
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3445
NS IDERNDUSTRIAL AUTOMATION + PROCESS CONTROL
WANT
INFORMATION
ON THE
automationindustry
SUBSCRIBE NOW at wwwiainsidercouk
Published by Spitzer and Boyes LLC Write in 15 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
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Frost says the push from developing
economies is important as the market
is technologically mature and seeing
restricted growth in developed econo-
mies This is particularly true in Europe
and North America where recent finan-
cial insta-
bility has
reduced capital expenditure across end-
user industries
Bill Moore senior vice president of
sales development and channel man-
agement for global bearings manufac-
turer SKF says ldquosmartrdquo products and
the expansion of robust reliability pro-
grams are helping to drive new invest-
ment particularly in developed coun-
tries where the cost to compete is
high Frost says the magnitude of
the existing global installed base will
strengthen the need for replacement
and upgrades adding to market de-
mand as well
Frost says despite the potential
in developing economies the focus
on price as a product differentiator
may lead to intense price pressures
among manufacturers and bring down
the value of the overall market in the
short term The growing trend among
consumers to choose low-cost Chinese
imports will complicate this challenge
As price and quality become stan-
dardized across the globe customers
will base more of their purchasing deci-
sions on value-added services accord-
ing to Frost This will push manufactur-
ers to create more maintenance-free
solutions such as lubrication-free
bearings that offer end-users savings
on service and replacement costs and
reduce downtimeldquoOffering a complete line of prod-
ucts with comprehensive services will
be another feather in the cap of ven-
dors looking to widen their consumer
baserdquo notes Frost Industrial Automa-
tion and Process Control Research
Analyst Guru Mahesh
Moore says the trend of outsourcing
manufacturing to regions where labor
and production costs are favorable is
becoming less of a factor
ldquoThe days when cheap labor made
a significant difference in where a prod-
uct is manufactured mdash particularly high
value-added products or high weight
and bulk products mdash are coming to
an end as the cost of transportation
storage and inventory balance out the
benefits of production costs where la-
bor is a smaller percentage of the cost
of manufacturingrdquo Moore says ldquoLocal
manufacturing development will indeed
come to developing countries as their
ability to create markets that generate
economies of scale that support local
production is a clear trend and one that
all manufacturers will pay attention tordquo
Moore says that development of
maintenance-free or predictive tech-
nologies and products will be a sig-
nificant advantage to everyone in the
Bearing amp Coupling Manufacturers Focus
onDEVELOPING Economies
amp EFFICIENCY InnovationBy Amy W Richardson
2 January 2015
Flow Control Magazine
|
gy
Anew study from Frost amp Sullivan (wwwfrostcom) fore-
casts steady growth for the overall bearings and couplings
market based on rapid industrial development in high-growth
regions Specifically Frost predicts development in Mexico
Indonesia Nigeria Turkey Brazil Russia India and Chinawill help boost the bearings amp couplings market from $2206
billion in 2013 to an estimated $2676 billion in 2018
The development of maintenance-freeor predictive technologies will helpboost growth in the bearings market For example SKF is developing products that will automatically notifyusers when a bearing or mechanicalrotating component is approachingthe end of its useful life Pictured hereis an SKF Microlog analyzer a por- table condition monitoring tool
COURTESY SKF
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
improved productivity through simplified solutions The powerful technology and tools ensure repeatable
reliable accurate measurements Easier access to process data allows for better troubleshooting process
optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
For daily product notes visit the lsquoFeatured Productsrsquo section flowcontrolnetworkcom
ON THE WEB
1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3845
FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
and benefits as well as grids of
instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
services provided for the
mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
Brought to you by Beamex
Your Source For Fluid Handling Videos
Go towwwflowcontrolnetworkcomfreeinfo
Select appropriate issue ofFlow Control Magazine
Select advertisements thatinterest you
Enter your email amp clickldquoSubmit Requestrdquo
1
2
3
4
PRODUCT
INFORMATION
ONLINE
Follow these 4 steps to receive freeproduct information from suppliers
FREE
FEATURED VIDEO How to Calibrate aPressure Measurement Loop
For more information about FlowTube
sponsor packs email FlowControlGrandViewMediacom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4245
THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
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Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545
![Page 10: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/10.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1045
Endress+Hauser Inc
2350 Endress Place
Greenwood IN 46143
infousendresscom
ww wusendresscom
Sales 888-ENDRESS
Service 800-642-8737
Fax 317-535-8498
Guided wave radar level products - built for safety precision and efficiency
bull Reliable non-contact measurement even for changing process conditions
bull HistoROMreg data management - concept for fast and easy
commissioning maintenance and diagnostics
bull Multi-Echo Tracking evaluation - highest reliability even with the
presence of obstructions in the vessel
bull Hardware and software developed according to IEC61508 up to SIL3(in homogeneous redundancy)
bull Seamless integration into control or asset management systems
bull Worldrsquos easiest proof test concept for SIL saves time and cost
wwwusendresscommicropilot-radar-level
The newest generation of Micropilot
Taking your process to the next level
Write in 7 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1145
HE OUTLOOK | News amp Notes
1 ISO15848 ldquoMeasurement test and qualification proce-
dures for fugitive emissionsrdquo
a Part I ndash ldquoClassification system and qualification proce-dures for type testing of valvesrdquo
b Part II ndash ldquoProduction acceptance test of valvesrdquo
2 API 622 ldquoType Testing of Process Valve Packing for Fugitive
Emissionsrdquo
3 End-user defined fugitive emission reduction requirements
Key aspects of valve testing per API 624 include
The standard covers rising and rising-rotating stem
valves up to 24rdquo diameter
Class 1500 valves are not covered
The test medium is methane
310 test cycles are required with three thermal cycles Temperature application range is from -29 C to 538 C
with last cycle 10 cycles user-defined (can be -45 C)
Re-tightening of gland bolts is not permitted during test
Valve stem test orientation is vertical
Several valves must be tested to achieve API 624 com-
pliance Similar industry principles applied to test valves
qualify two nominal sizes smaller one size larger and one
pressure class below
Allowable leakage is 100 PPM maximum
Gate and globe valves need to be tested separately
For example Gate Valves per API602 four tests API600
eight tests (up to 20rdquo diameter) API 603 eight tests andfor Globe Valves per API 602 four tests
Test valves should be production valves not specially
manufactured test valves
As a result of the release of API 624 testing companies have
been gearing up for an increase in the number and size of
test valves and new test houses are coming to market Withthis in mind implementation of API 624 needs to be carefully
monitored and claims from valve manufacturers should be
validated by requesting to view test results Important factors
to be mindful of include
Number of cycles on some valves could be detrimental
to packing as certain smaller size valves donrsquot come with
grease ports to keep the stem lubricated all of the time
Test failures of valve stem threads yokes and glands
Grease traps into packing and causes leakage
At higher temperatures a few greases create volatile
organic compound and burn off
Testing in vertical generates more heat in yoke area
Certain challenges need a good testing company that has
experience in testing on fugitive emissions and provides
guidelines to manufacturers in terms of use of packing valve
grease testing requirements etc
A preliminary survey was conducted with end-users regard-
ing current utilization and application of API 624 For a sum-
mary of responses from this survey visit flwctrlcom1oWijWz
Gobind Khiani PEng is with Fluor Canada Ltd Khiani has
spent 20-plus years in the energy and power business and 10-
plus years in the Western Canadian oil and gas industry Hecan be reached at 403 850-6982 or gobindkhianifluorcom
Valve Standards UpdateEnd-users ramp up compliance efforts for API 624
as new specifications emerge on the horizon
8 | January 2015
Flow Control Magazine
By Gobind Khiani
In the May 2014 issue of Flow Control (page
16) the new standard API 624 ldquoType Testing
of Rising Stem Valves Equipped with Graphite
Packing for Fugitive Emissions First Editionrdquo was
addressed This standard which was published
and put into effect in February 2014 estab-
lishes guidelines for testing industrial valves for
emissions compliance Since the publication ofthe May article further requests from industry
have spurred the creation of another specifi-
cation API 641 ldquoType Testing of Quarter-Turn
Valvesrdquo and an API ldquoPiping and Valvesrdquo commit-
tee has been formed Regulators and end-users
are also working on
1992 1998 2003 2008 2013 2020
4
35
3
25
2
15
1
05
0
M i l l i o n o f
t o n n e s y e a r Will API 624
have a stepeffect in reducing
fugitiveemissions
Global valve fugitive emissions
End User response at best
End User response actual
S O U R C E G O B I N D K
H I A N I
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1245
Intelligent Features to Boost Global WaterDesalination Pumps Market
The Global Water Desalination
Pumps Market is expected to grow
at a CAGR of 77 percent from 2015 to
2019 according to a new report from
TechNavio (wwwtechnaviocom)
The report shows demand for water
treatment has increased significantly in
developing countries where fresh wa-
ter resources can be scarce Providing
clean and potable water to huge popu-
lations has become a priority which is
pushing the demand for water desalina-tion pumps in the market according to
TechNavio
The report emphasizes the emer-
gence of intelligent pump systems as
a major driver of market growth In-
telligent pumps possess the ability to
regulate flow and pressure and these
systems can automatically adjust to
process and pump system changes
ldquoIntelligent pump systems are be-
ing adopted by many manufacturers
because of the high level of fault toler-
ance ability which leads to a significant
reduction in the total cost of owner-
shiprdquo said Faisal Ghaus vice president
of TechNavio in a news release ldquoThe
adoption of these systems will also
help industries comply with current Eu-
ropean Union regulations in relation toreduction in energy consumptionrdquo
The growing demand for clean wa-
ter worldwide will continue to augment
the demand for water desalination sys-
tems which will propel the Global Water
Desalination Pumps Market during the
forecast period
trendlines
wwwflowcontrolnetworkcom January 2015 | 9
Write in 8 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
Intelligent pump sys-tems are being adopt-
ed by many manufac-
turers because of the
high level of fault tol-
erance ability which
leads to a significant
reduction in the total
cost of ownership
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1345
HE OUTLOOK | News amp Notes
10 | January 2015
Flow Control Magazine
Hydraulic Fracturing WaterTreatment amp Reuse Expected to Soar
Wastewater treatment spending for
hydraulic fracturing is expected to
grow almost three-fold from $138 mil-
lion in 2014 to $357 million in 2020 in
the US according to a new report from
Bluefield Research
The US hydraulic fracturing industry
consumes over 1 billion barrels of wa-
ter annually producing 450ndash500 mil-
lion barrels of contaminated water for
disposal with only about 14 percent
treated and reused Bluefield cites watersupplies increasingly at risk tighter regu-
lations emerging in key states and costs
of disposal on the rise as factors con-
tributing to the substantial rise in water
treatment and reuse which is expected
to account for 27 percent of total pro-
duced and flowback water by 2020
Overall the US hydraulic fracturing
industry will spend $638 billion in 2014
on water management Water transport
and disposal costs will account for 66
percent of the total water managementspent this year with treatment compris-
ing roughly 2 percent
Bluefield reports water scarcity in
Western US states has had little im-
pact to date on fracturing water supply
but that is likely to change if droughts
persist Meanwhile state regulators are
beginning to tighten control of produced
water disposal In Pennsylvania where
policymakers in 2010 placed discharge
limits on wastewater from unconven-
tional oil amp gas operations statewide
treatment and reuse rates for the Mar-
cellus jumped to 90 percent in 2014
The increasing cost of transport and
injecting water into wells mdash now ac-
counting for 66 percent of water servicesspending mdash and the improving cost
structures of treatment provide another
driver of reuse Bluefield reports Well
operators that employ treatment and re-
use solutions spend on average $880
per barrel of water used compared to
$1020 per barrel of water trucked and
injected into wells although cost com-
parisons are site specific
ldquoFracking has been the Wild West for
the US water industryrdquo said Reese Tis-
dale president of Bluefield Research ina prepared statement ldquoThere are three
reasons for this first there has been
an explosive build-out of fracking well
installations now surpassing 126000
Second there has been a lack of clear
regulation on water management in key
markets And third there is not a one-
size-fits-all treatment solution for frack-
ing meaning solutions providers have
had to ascend a steep learning curve
to treat the variable wastewaters that a
single well is capable of producingrdquo
Tisdale notes that these inhibitors
while still acute are beginning to take on
a new form This is partially due to signifi-
cant gains in water management experi-
ence realized adoption of more efficientwater management strategies among
well operators and the emergence of
new policy mechanisms from regulators
that are playing catch-up with the fast-
moving hydraulic fracturing industry
trendlines
Treatment2
Disposal
6
Supply10
Storage22
Transport60
US $638Billion
S O U R C E B L U E F I E L D R
E S E A R C H
Write in 23 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
Industry-Leading
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Temperature Measurement Solutions
bull Probe type industrial RTDsbull Electronic temperature switchtransmitter bull Vapor-actuated remote thermometersbull Digital temperature indicatorsbull Platinum resistance temperature transmitterbull Compact OEM temperature transmitter bull Industrial amp instrument type bimetal thermometersbull Thermowells
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1445
New Technique Could ReduceEnergy Required for Oil Refinement
UK scientists have developed a
technique they say has the poten-
tial to dramatically reduce the amount
of energy required for the refinement
of crude oil
Professor Martin Schroumlder and Dr
Sihai Yang from The University of Not-
tingham (wwwnottinghamacuk ) have
led a multi-disciplinary team of scien-
tists from Nottingham the Science and
Technology Facilities Councilrsquos (STFC)
ISIS Neutron Facility Oak Ridge Na-tional Laboratory and Diamond Light
Source to discover a porous material
that works like a chemical sponge to
separate a number of important gases
from mixtures generated during crude
oil refinement
According to a news release from
The University of Nottingham the ex-
isting industrial process uses ldquohuge
amounts of energy to separate and pu-
rify these gases so the new technique
has the potential to revolutionize the oil
industry by significantly reducing car-
bon emissions and making the process
more environmentally friendlyrdquo
Commercially UsefulCrude oil is a raw material that is
refined to produce fuel for cars toheat homes and to create polymers
and other useful materials It is made
up of a complex mixture of hydro-
carbons (chemical compounds that
contain only hydrogen and carbon) of
which certain components are espe-
cially commercially useful
One industrial process used to
achieve hydrocarbon separation is
called ldquocryogenic distillationrdquo which is
widely used worldwide and uses vast
amounts of energy to generate the high
pressures and cryogenic temperatures
required to ensure efficient separation
research amp development
wwwflowcontrolnetworkcom January 2015 | 11
PLASTIC CONTROL VALVES FORALL YOUR CORROSIVE APPLICATIONS
PO Box 938 bull Angleton TX 77516Tel (979) 849-8266 bull wwwcollinsinstcom
Collins plastic control valves are
highly responsive control valves
designed for use with corrosive
media andor corrosive atmos-
pheres
Collins valves feature all-plastic
construction with bodies in PVDF
PP PVC and Halar in various body
styles from 12 - 2 with Globe
Angle or Corner configurations and
many trim sizes and materials
Valves may be furnished without
positioner for ON-OFF applications
Call for more information on our
plastic control valves
Write in 9 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1545
of hydrocarbon mixtures into pure components
However researchers say an innovative solution may
have come in the form of a novel chemical sponge This
porous material a metal-organic framework was devel-
oped by the same team at Nottingham just two years ago
Now in research published in Nature Chemistry for the
first time scientists have proven that it can be used toseparate hydrocarbon mixtures without the need for high
process pressures or very low process temperatures
Reusable MaterialsMade from cheap organic materials aluminum nitrate
salt and water the porous material called NOTT-300 is
able to adsorb different gases found in mixtures of hydro-
carbons at different rates making it possible to sepa-
rate them and extract the most useful ones NOTT-300
requires less energy to function than existing methods
as it operates at ambient temperatures and normal pres-
sures researchers say The gases that are adsorbed intoNOTT-300 can be removed without a significant energy
input and therefore the material can be easily reused
The team of scientists from Nottingham used Diamond
the UKrsquos synchrotron science facility as well as STFCrsquos
ISIS Neutron Facility and Oak Ridge National Laboratory
the UKrsquos and USArsquos world-leading neutron facilities re-
spectively to prove that the sponge works under real-life
conditions
Professor Martin Schroumlder Dean of the Faculty of Sci-
ence at Nottingham said in the news release ldquoIt is a very
important to be able to separate different hydrocarbons ef-
fectively and efficiently with low-energy consumption Po-rous solids such as the metal-organic framework system
studied here represent important materials for the future
development of low-energy separation technologies We
are most grateful to our collaborators at ISIS Neutron Fa-
cility Oak Ridge National Laboratory and Diamond Light
Source in bringing this work to fruitionrdquo
Significant Impact on Oil IndustryDr Sihai Yang the winner of Diamond Young Scientist
and BTM Willis Prize is a Senior Research Fellow at
Nottingham He led the project together with Professor
Martin Schroumlder Yang said ldquoWith the help of advancedcentral facilities like Diamond ISIS and ORNL we have
developed a new separation technique which can poten-
tially reduce the energy usage associated with oil petro-
leum and chemical industries which require the separa-
tion of raw hydrocarbons from crude oil
The discovery of the new material NOTT-300 could
have a significant impact on the oil industry by removing
the necessity for some energy-intensive refinement pro-
cesses researchers say
The research was funded by Engineering and Physical
Sciences Research Council (EPSRC) the European Re-
search Council (ERC) The University of Nottingham andLeverhulme Trust
12 | January 2015
Flow Control Magazine
Write in 21 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
No media contact - No risk of leaks
No process Shut-Downs for installation
No bypass needed
For hazardous area locations (FM approved)
Monitor your Total Acid Consumption
Increase your Plant Up-Time
Balance your Processes
PIOXreg S
PIOXreg S - the evolution of flow and concen-
tration measurement in acid production
Non-intrusive mass flow concen-
tration and density measurement
of aggressive media
wwwpiox-scom
wwwfleximcom
Contact us for a free trial measurement
Thank you for your votes and
making PIOXreg S a Flow Control
Awards Winner
THE OUTLOOK | News amp Notes
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1645
The ASCO trademark is registered in the US and other countries The Emerson logo is a trademark and service mark of Emerson Electric Co copy 2014 ASCO Valve Inc
1-800-972-ASCO (2726) | e-mail info-valveascocom | wwwascovalvecomSpoolValve
Now get spool valves with industry-leading ASCO solenoid technology built in
Delivering unmatched performance and durability our compact new valves are
perfect fits for all your onshore near-shore or offshore upstream control panels A
range of easily configured features and options includes superior temperature and
pressure ratings plus low-power models The industryrsquos toughest testing ensures
every rugged stainless steel valve meets or exceeds specifications Plus we design
and support every spool valve we make Ask for ASCO the ultra-reliable choice for oil
and gas control panels
These new spool valves will fit right in
Write in 22 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 174514 | January 2015 Flow Control Magazine
PPLICATIONS CORNER | Process Instrumentation
This is the final article in a series based on the troubleshoot-
ing of a mysterious unit shutdown due to flowmeter perfor-
mance problems
If yoursquove followed this column for most of 2014 you know
that what should have been a liquid ammonia stream to the
feed plant became problematic due to the occurrence of
bubbles of ammonia gas These bubbles caused an ultrasonic
flowmeter in a unit to indicate zero flow and caused the reactor
to scram (shut down) under warm operating conditions The source of the bubbles was traced back to the pres-
sure drop associated with a control valve located at the
exit of the liquid ammonia tank farm
This issue was resolved by identifying the problem
and fixing it at its source This was a pragmatic ap-
proach at the time (early 1980s) given the operation
of the cooling system in the unit and the limited selec-
tion of applicable flowmeter technologies
By the early 1990s changes were implemented that elim-
inated all process cooling requirementsmdashexcept for the small
jacketed cooler upstream of the liquid ammonia flowmeter In
other words after these changes the entire cooling system
would be operated and maintained to cool a few meters of
one small ammonia pipe Coincidently at about the same
time Coriolis mass flowmeters became more mature and
could reasonably measure the mass flow of liquid streams
with homogeneous low levels of vapor
The convergence of these two events resulted in another
approach to the problem that was not available in the early
1980smdashie install a Coriolis flowmeter that could operate in
the presence of bubbles The purchase and installation of a
Coriolis mass flowmeter was given high priority given its im-pact on unit operation economics and safety (by eliminating
the ldquomidget-makerrdquo (see March 2014 page 14))
Plant requirements and the technology that can meet
plant needs keep changing An excellent solution today can
become outdated in just a few years However there are few
substitutes for understanding fundamentals when addressing
a problem In other words there can be more than one way
to skin a cat FC
wwwspitzerandboyescom
Problem Solved AgainA Coriolis mass flowmeter provides a better solution
F o r B e t t e r P i p i ng S y s t e m P e r f o r m a nc e hellipFor Better Piping System Performancehellip
I d e a l f o r Ag g r e s s i v e C h e m i c a l s
1384 POMPTON AVENUE CEDAR GROVE NEW JERSEY 07009
973-256-3000 bull Fax 973-256-4745www p l as t om a t ic co m bull i n f o p la s t om a t ic co m
bull Rugged thermoplasticshandle corrosive andultra-pure chemicaltreatments
bull Constant pressure enhances
pump performancebull Prevents overpressure in
piping system
bull Wide range of pressuresettings
bull PTFE shaft and diaphragm designs
bull 1 4rdquo - 3rdquo sizes in PVC CPVC PVDFPolypro and PTFE
bull First State approved
thermoplastic valve for
anti-siphon applications
Write in 10 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
David W Spitzer
Ammonia Gas | Coriolis Flowmeter | David W Spitzer | Scram | Troubleshooting
FLOWSTREAM Find related content flowcontrolnetworkcom
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and Boyes
LLC offering engineering seminars strategic marketingconsulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer can be reached at 845 623-
1830 or at wwwspitzerandboyescom
The purchase and installation of a
Coriolis mass flowmeter was given
high priority given its impact on unit
operation economics and safetyldquordquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1845
Smart Valve Positioner
Beyond Control The NEW Research Controlreg SRD positioner does
everything you expect any valve positioner to do
plus more The SRDrsquos comprehensive diagnostics tool
continuously monitors for fugitive emissions delivers
real-time performance statistics and facilitates both
proactive and reactive process management Available
with integrated network communications the SRD is
compatible with Research Control valves and most other
pneumatically-actuated valves
Visit wwwbadgermetercomSmart-Valve-Positioners or
call 877-243-1010 for more information today
copy 2015 Badger Meter Inc
RESEARCH CONTROL is a registered trademark of Badger Meter Inc
Write in 11 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1945
Process improvements to increase yield or cut manufactur-
ing costs typically require enhanced process control but the
installed base of measurement instrumentation in a process
plant may simply be unable to facilitate improvements because
of age inadequate performance or unreliability Maintenance
cost and unscheduled process downtime for an aging process
plant can be very damaging to the balance sheet Upgrading
to new more accurate and more reliable instrumentation can
be prohibitively expensive New plant construction must alsomaintain a focus on optimizing costs for the process control
infrastructure The budget approval decision for new plant
construction must weigh such costs against projected market
conditions for the products that the plant is intended to manu-facture In todayrsquos volatile global marketplace return on invest-
ment calculations for plant upgrade or new plant construction
projects may go through several iterations before the trigger is
finally pulled or indeed not pulled
This article describes advances in two-wire instrumenta-
tion specifically in relation to flowmeters that have taken
place in the past few years and the significant cost benefits
that this new technology can realize for plant builders and op-
erators in terms of capital investment and cost of ownership
The Significance of Two-Wire Loop Power
A survey involving 204 participants in the chemical indus-try across Germany Switzerland the UK Canada and the
United States (Manfred Koenig PhD KIM Ludwigshafen
Germany 2006) revealed an 87 percent preference for two-
wire instrumentation versus four-wire in process applications
and 89 percent for utilities This overwhelming preference
may stem from the fact that older process plants were built
with two-wire twisted-pair cable networks connecting all
process units and measuring instruments together in an
overall plant control scheme
However these existing cables are relatively unsophisti-
cated and incapable of supporting anything but low-energy
instrumentation that is insensitive to interference from otherelectrical sources that might be sharing the same cable con-
duit Further the low energy levels supported by these two-
wire loops are more easily rendered safe in terms of explo-
sive risk in hazardous areas containing flammable materials
Many older process plants are also likely to have a significant
installed base of flowmeters employing pre-war (pre-1945)
technology such as positive displacement (PD) turbine vari-
able area (VA or Rotameter) and differential pressure (dP)
Market data firm Flow Research Inc (wwwflowresearch
com) indicates collectively a future compound negative annual
growth rate approaching minus 3 percent to 5 percent for PD
turbine and VA flowmeter types while dP is expected to keeppace with market growth (World Market for Flowmeters 2010)
YSTEMS DESIGN | Flow Measurement
16 | January 2015
Flow Control Magazine
The Two-Wire
ADVANTAGENew wiring options enable modern instrumentsto drive cost savings in existing plant systems
By Steve Milford
Advances in two-wire instrumentation have enabled mod- ern technology to be employed to the advantage of older
plant and process systems
Some chemical manufacturing plants are
competing for survival not only externally
against other global companies but also
internally among the global facilities of theirown company Other industry sectors face
similar challenges
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2045wwwflowcontrolnetworkcom January 2015 | 17
The Need to Replace Older TechnologiesUntil the 21st century two-wire loops were only able
to support these relatively unsophisticated instruments
which convert their measurement by various means into a
4-20mA output or pulse signal to the control system The
more advanced post-war flowmeter technologies such as
Coriolis ultrasonic or electromagnetic flowmeters have
until just eight years ago required a dedicated power sup-
ply for their function in addition to the output loop and
thus a four-wire infrastructure was required as a minimum
Therefore upgrading older two-wire meter devices to moremodern four-wire technology could require significant
expenditure in terms of the installation of separate power
cables and supply modules
There was a major breakthrough in 2006 when a true
two-wire loop-powered inline liquid ultrasonic flowmeter
was introduced (Figure 1) The nature of this breakthrough
was innovation in device power management This was the
missing piece up to that point because to be a true loop-
powered device the meter had to directly provide a full 16
mA span using less than 36 mA of remaining loop current
and less than 1 Watt of electrical energy The flowmeter
operated on a single 4-20 mA HART two-wire loop wasremotely powered by a DC supply was certified Class 1 Divi-
sion 1 and could be deployed as Intrinsically Safe through
the use of an approved safety barrier
A true two-wire loop-powered Coriolis flowmeter followed
in 2011 (Figure 2) employing a new and more advanced
common electronics platform A two-wire loop-powered inline
ultrasonic flowmeter for low-pressure gas was introduced in
2012 and a second two-wire loop-powered Coriolis meter fol-
lowed in 2013 offering improved measurement performance
and an additional high-performance meter tube material
Electromagnetic and vortex flowmeters had already been
available for some years in two-wire loop-powered form butimproved performance resulted as these designs were incor-
COURTESYENDRESS+HAUSER
Figure 1 A two-wire ultrasonic flow- meter released in 2006 operated ona single 4-20 mA two-wire loop
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 214518 | January 2015
Flow Control Magazine
porated into their new common electron-
ics platform in 2013 So all the ldquomodernrdquo
flow measurement technologies mdash that
is to say those introduced post-war mdash
have become available as two-wire loop-
powered devices with one exception
namely thermal mass (thermal disper-
sion) meters Unfortunately the power
requirements for this technology exceed
what is currently deemed possible withtwo-wire loop-power management
Payback forTechnology UpgradeConsider a 1rdquo process line
containing a liquid process
ingredient costing $1lb at a
mass flowrate of 150 lbmin-
ute We have $150minute
flowing in the line translating
to $9000hour and $72000
per eight-hour shift That cal-culates further to $360000
per five-day working week and
for a working year of 40 weeks for
example that is $144 million Assume
the existing device is a turbine flowmeter
Now imagine a two-wire loop-
powered Coriolis mass flowmeter is
installed in place of the existing meter
The line would need to be drained and
probably one process flange replaced
allowing the Coriolis to fit mechanically
in place of the turbine However thetwo-wire loop already used for carrying
the existing meterrsquos flow signal to the
control room can be used unaltered
for the complete electrical installation
aspects of the Coriolis flowmeter
The upside of the change is signifi-
cant and clear cut Assuming the exist-
ing meter measurement uncertainty was02 percent of reading then measure-
ment uncertainty improves through use
of Coriolis to 01 percent of reading
giving a 01100 x $14400000 im-
provement in control of the ingredient
annually or $14400 A two-wire Coriolis
mass flowmeter with 01 percent mass
flow accuracy would be paid for in ap-
proximately 6-8 months In practice the
improvement in measurement uncer-
tainty would be greater as the operator
would gain temperature and density in-formation from the Coriolis and the mea-
surement would be devoid of any fluid
property dependence Viscosity change
for example can have a major impact on
turbine meter performance Mechanical
wear and tear that turbine meters even-
tually experience which causes them to
under-register flow is precluded by mod-
ern devices like Coriolis
Furthermore if the process ingredient
was being blended with another then ad-
ditional process improvements could berealized through in-line blending control
using Coriolis technology for final density
as the control point It is possible to have
dual 4-20 mA outputs from two-wire
loop-powered meters but as the main
4-20 mA output representing the prima-
ry variable is also HART then an external
HART Loop Converter or HART IO card in
the control system can provide second-
ary tertiary and quaternary variables as
4-20 mA signals A Coriolis meter is trulya multi-variable device Certain two-wire
devices are also available with Profibus
or Foundation Fieldbus communication
Cutting Wiring CostsIn 2003 WIBEXERA (International
Instrument Usersrsquo Associations) Report
T 2732 X 03 was published and it pro- vided an average survey of prices quoted
in projects at that time for the provision
of power supplies for four-wire instru-
ments The price ranged from euro1200
to euro1800 per instrument depending
upon design and plant characteristics
for an average cost of euro1500 (about
$2000) It would be reasonable to
assume an inflationary factor of 2 per-
cent per annum giving an approximate
current-day figure of $2500
From another source within thechemical industry an estimation of
$40foot to $50foot was given for in-
stallation of four-wire cabling For a
linear 50-foot cable run with for ex-
ample a 10-foot vertical at each end
this equates to $3150 Actual costs
and budget estimates have been given
as high as $10000
The Extent of the Opportunity The modern post-war flow measure-
ment technologies have different powerrequirements and consequently they
are not all available for the
same size range in two-wire
loop-power form For example
two-wire Coriolis flowmeters
are limited to 2rdquo diameter
electromagnetic and inline
low-pressure gas ultrasonics
are limited to 8rdquo and vortex
and inline liquid ultrasonic are
limited to 12rdquo
Nevertheless for thechemical industry in particu-
lar perhaps two-thirds of the
process pipes in a plant will be no larger
than 2rdquo and even when the host process
pipe is larger a correctly sized flowmeter
can still be less than 2rdquo There is consid-
erable scope for two-wire loop-power to
deliver value for flow measurement ap-
plications with total safety
The virtues of Coriolis technology
have been covered but what about
other two-wire technologies An elec-tromagnetic flowmeter in two-wire form
YSTEMS DESIGN | Flow Measurement
In todayrsquos volatile global mar-
ketplace return on investment
calculations for plant upgrade or
new plant construction projects
may go through several itera-
tions before the trigger is finally
pulled or indeed not pulled
ldquo
rdquo
COURTESYENDRESS+HAUSER
Figure 2 Two-wire Coriolis flowme- ters became available in 2011
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2245
can be used on water wastewater or
a light water-based slurry provided the
fluid has around a 20 microSeimenscenti-
metre (microScm) electrical conductivity
A magnetic flowmeter is full bore un-
less flowrates dictate a reduced meter
size in the interests of performance and
so there are no intrusions into the flow
stream and no pressure loss An accu-
racy of 05 percent of reading is normal
from a two-wire magnetic meter and a
modest five diameters (5D) of straight in-let run is needed to avoid error from up-
stream flow disturbances When the fluid
exhibits insufficient conductivity then
the same performance and installation
requirements can be met by an inline ul-
trasonic flowmeter provided the liquid is
essentially clean and bubble-free
For gas or steam applications a vor-
tex meter is the normal choice Using a
built-in temperature sensor a two-wire
loop-powered vortex meter can calculate
mass flow of saturated steam using in-ternal steam tables An external pressure
input allows mass flow of steam to be ac-
curately calculated even when saturated
steam becomes superheated as can oc-
cur downstream of a pressure regulating
valve With mass flow known the vortex
meter can calculate energy and heat flow
A new and exciting development is
the ability of the vortex meter to indicate
wet steam and calculate dryness frac-
tion or steam quality For safety and ef-
ficiency saturated steam should be dry
and free from condensate that is to say
it should possess a high steam quality
factor However the dry or wet state of
saturated steam can sit on a knife-edge
and shift to the opposing state due to
the slightest change in process condi-
tions Rapid and reliable indication of
this change of state is now available
Perhaps the most astonishingachievement in the power management
of two-wire loop-power flowmeters is
that of the ultrasonic biogas meter It is
now possible not only to measure the
flow of wet dirty variable composition
and low-pressure anaerobic digester
gas landfill gas and coal bed methane
gas with a two-wire loop-powered ultra-
sonic flowmeter but also the same de-
vice uses an inbuilt temperature sensor
in combination with measured sound
velocity to calculate methane contentcalorific value and energy flow
Technology to Take UsForwardModern flow technologies provide instru-
ment engineers with vital self-monitoring
information The format of such infor-
mation is easier to understand and act
upon when presented in accordance
with harmonized international guidelines
for online plant asset management eg
NAMUR Standard 107
Continuous plain-text self-diagnostic
and process-related information with
suggested remedies (Figure 3) make it
possible for instrument engineers andoperators to take action at the appro-
priate time mdash immediately or during
the next scheduled shutdown mdash saving
time and money by knowing the exact
health of their measuring point and the
probable actions required to rectify any
abnormal conditions Device verifica-
tion offering third-party validated trace-
ability can be performed on demand ei-
ther locally or remotely from the control
room without the expense of a man in
the field Calibration is then avoided ordeferred without process interruption
Where a process plant has a large
installed base of older mechanical tech-
nologies the decision to embark upon a
program of replacement for plant mod-
ernization cannot of course be taken
easily There are the stocks of spare
parts to consider along with the plant
instrument technicians who are trained
on and at ease with the old devices
However a process plant that retains
the older technology going forward willbe at risk and may find it increasingly
difficult or even impossible to maintain
a cost position that competes effective-
ly in the global market FC
wwwusendresscom
wwwflowcontrolnetworkcom January 2015 | 19
Steve Milford
is a Flow Product
Business Manager
for Endress+Hauser
Inc in Greenwood
Ind He has been
involved in flow
measurement since
1983 and has been
actively involved with standards devel-
opment for flow technology within the
International Standards Organization
(ISO) and the British Standards
Institute Mr Milford can be reached
at stevemilfordusendresscom
Steve Milford
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Coriolis Flowmeter | Magnetic Flowmeter | Two-Wire | Ultrasonic Flowmeter | Vortex Flowmeter
Figure 3 A modern instrumentrsquos display module can provide continuous plain- text self-diagnostic and process-related information
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2345
The bottom line is the volume of gas under one set of
pressure and temperature conditions is not the same as it
would be for the gas under different conditions Why is thisimportant Without compensation for compressibility read-
ings taken by gas flowmeters can result in measurementsmdash
and costs to the buyermdashsignificantly lower or higher than they
should be
The flow of gas in a system can be accounted for and
reported in a number of ways such as by volume by mass
flowrate and by energy Inline turbine meters can offer both
reliability and accuracy in measuring gas flow when matched
with a monitor capable of calculating and displaying results
that have been adjusted for the nature of the gas and impor-
tantly the pressure and temperature
Measuring Flow with an Inline TurbineFlowmeter
With an inline turbine meter gas flows into the meter through
a length of piping that helps to pre-condition the flow by
reducing undesirable swirls and asymmetry Where consid-
ered necessary a flow straightener may even be installed in
line to create a uniform flow profile to the extent possible
As can be seen in Figure 1 a rotor support within the tur-
bine housing further conditions the flow and directs it through
the blades of the rotor High-precision ball bearings allow the
rotor to freely rotate on the shaft
The rotorrsquos rotational speed is directly proportional to the velocity of the fluid passing through the meter The rotor itself
incorporates magnets (or magnetic blades depending on thedesign) while the housing is non-magnetic
A proximity sensor (also known as a pickup coil) is located
in line with the rotor and detects the electrical pulses gener-
ated by the ferrous rotor spinning through the magnetic field
Each pulse represents a discrete volume of gas The out-
put frequency provides the indication of the gas flow rate and
the accumulated pulses over a specified time represent the
total volume of fluid for that measurement period
Need for Calibration The flowrate of the gas through the meter cannot be deter-
mined accurately unless the meter is calibrated The fac-tory calibration determines the meterrsquos constant known
as a K-factor which is then inputted into the gas monitor
PPLICATION NOTES | Flow Measurement
20 | January 2015
Flow Control Magazine
COMPENSATING for
Compressibility inMeasuring Gas Flow Why K-factor adjustment is essential foraccurate inline turbine flow measurement
Unlike crude oil and other liquid fossilfuels natural gas poses a challenge
in monitoring the quantity of gas flowing
through pipelines While liquids do not com-
press gases do and the mass flowrate of
gas being transmitted through gathering
lines depends on both the pressure and
temperature
By Kevin Clark
Figure 1 Internal components of a liquid turbine flowmeter
C O U R T E S Y
T U R B I N E S
I N C
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2445
Wondering Whether the
Pump Guy Seminar
Is for YouCheck out the ldquoPump Guy Insightsrdquo
video series flwctrlcompginsights
PUMP GUY INSIGHT 1NPSHa vs NPSHrmdashWhy all pumps need gauges
PUMP GUY INSIGHT 3How to Operate Your Pump at Best Efficiency
PUMP GUY INSIGHT 5Head vs Flow
PUMP GUY INSIGHT 2 Your Pumps Are Constantly Moving On Their Curves
PUMP GUY INSIGHT 4 The Role of the Pump Reliability Chain
PUMP GUY INSIGHT 6How to Read a Pump Curve
PARTNER SPONSORSFor more information and to register
for upcoming Pump Guy Seminars
visit FlowControlNetworkcomPumpGuy
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2545
PPLICATION NOTES | Flow Measurement
22 | January 2015
Flow Control Magazine
Gas flowmeters measure the actual volume of gas passing
through the meter per minute irrespective of pressure and
temperature1
The volumetric flowrate of a gas is often corrected to
ldquostandardizedrdquo conditions of pressure and temperature While
ldquostandardrdquo conditions can vary depending on the definition
in the US this typically means a pressure of 1473 PSIA(pounds per square inch absolute) and a temperature of 60 F
The flowrate measurement is reported in standard cubic feet
per minute (SCFM)
Compensating for changes in pressure and temperature is
critical Consider a meter system setup for flowing conditions
of 60 PSIG (pounds per square inch gauge) and 60 F and the
line pressure decreases to 50 PSIG while the temperature
remains constant The difference in SCFM between the two
is more than 15 percent which would cost the buyer more
for the gas than it should As Table 1 demonstrates even a
small variation in pressure will result in a surprisingly high er-
ror percentage
Automation of the K-Factor The K-factor is established by an initial factory calibration In
the case of a non-compensated flow monitor any variations
in pressure and temperature will result in manual adjust-
ments needed to the K-factor In order to maintain accurate
flow measurement users must monitor pressure and temper-
ature and make corresponding adjustments to the K-factor To eliminate these manual adjustments some suppliers offer
a flow monitor that automatically adjusts for any changes in
pressure and temperature
These monitors provide accurate flow measurement regard-
less of changing environmental conditions in some cases sup-
porting applications with pressures as high as 15000 PSIG and
temperatures between -350 F to 350 F with a standard accura-
cy of +-1 percent over a flow range of 05 ACFM to 650 ACFM
Final NotesDuring the operation of a flowmeter system the ability to obtain
a readout mdash and to adjust for line pressure and temperaturechanges mdash is sometimes compromised by a lack of electric
power This issue is especially true along gas pipelines in remote
areas To overcome this limitation some manufacturers have
designed low-powered flow monitors which can operate for up
to on year on a single lithium D-cell battery
It is important for users to recognize the effects of the
compressibility of gas As such the quantity of a gas flow-
ing through a gas flowmeter depends on the pressure and
temperature In order to ensure accuracy any flowmetering
system must employ a means to correct for these effects
Otherwise the readout is certain to be in error and could be
unnecessarily costing money This is particularly crucial onwellhead production and in billing scenarios FC
wwwturbinesincorporatedcom
Notations1 The measurement factor in the US is known as the
ACFM actual cubic feet per minute (Metric units are typically
ACMH actual cubic meters per hour)
Table 1 Error induced by line pressure changes
Constant Temperature with Varying Pressure
Pressure Temperature PulsesSCF Error
50 60 2556027821 1546
51 60 2517123288 1370
52 60 2479385307 1199
53 60 2442762186 1034
54 60 240720524 873
55 60 237266858 717
56 60 2339108911 566
57 60 2306485356 418
58 60 2274759285 275
59 60 2243894166 136
60 60 2213855422 000
61 60 2184610304 132
62 60 2156127771 261
63 60 2128378378 386
64 60 210133418 508
65 60 2074968632 627
66 60 2049256506 743
67 60 2024173807 857
68 60 1999697703 967
69 60 1975806452 1075
70 60 1952479339 1181 Flow Measurement | K-Factor | Measurement
Accuracy | Turbine Flowmeter
Find related content flowcontrolnetworkcomhellipSearch on
FLOWSTREAM
Kevin Clark is senior develop-
ment engineer for Turbines Research
amp Development LLC Turbine RampD is a
subsidiary and the research and techni-
cal support arm of Turbines Inc which
serves a range of industries and applica-
tions from oil amp gas to cryogenic liquids
to custody transferKevin Clark
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2645
Pumps Bearings amp Seals TECHNOLOGY REPORT
FEATURES
SYSTEMS DESIGN
The ComplicatedCase of
Compressors
withSide-Streams
24 28 32BEST PRACTICES
How PumpingSystems
AffectSealing
Performance
TECH OUTLOOK
BearingSuppliers
Drive Gains InDeveloping
Markets
wwwflowcontrolnetworkcom January 2015 | 23
S P E C I AL S E C T I O N
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2745
The design and operation of compressors with side-
streams has always been difficult because flow entering the
compressor needs to be mixed with the core flow already
in the compressor (compressed in section-1) in a manner
that does not degrade the aerodynamic performance of sur-
rounding sections Minimizing losses and ensuring proper
mixing of the side-stream flow and core-flow are required to
ensure effective performance of a compressor of this sort
Key considerations for an application involving compres-
sors with side-stream flow include
The plant process typically dictates the side-stream
flange pressure
The impellers upstream of the side-stream should
achieve the necessary pressure for the core-flow
The side-stream flow is typically at a temperature dif-
ferent from compressor core-flow temperature
Process plants need some degree of operational flex-
ibility ie the ability to support variations in core-flow condi-
tions and side-stream conditions
Modern process plants are usually specifying more than
one operating conditions (sometimes two or more manda-
tory conditions) which can present challenges to compres-
sors with side-streams Adding to these issues modern
compressors should operate with much higher impeller tip
The COMPLICATED CASE ofCompressors with Side-StreamsConsidering key system design requirements
to ensure operational efficiency By Amin Almasi
4 January 2015
Flow Control Magazine
|
y
g
Some compressors in certain applications
have one or more incoming side-streams
(or side-loads) that introduce side-stream
flow to mix with the core flow In other words
a radial side-stream inlet is utilized in multi-
impeller centrifugal compressors to introduce
additional gas into the mid-stage of a com-
pressor This design enables optimization in
some process plants However the flow dis-
tribution after the junction of the side-stream
and the main return channel of the upstream
section can significantly affect the perfor-mance of the next section of compressor
In most cases the pressure levels at these
side-streams should be accurately predicted
to meet the theoretical performance
Compressor station at a natural gas processing plant
R U D M E R Z W E R V E R I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2845
speeds and inlet Mach numbers compared to previous
generations of compressor technology
Likewise side-streams are now com-
monly used with medium-sized and
large-sized compressors (eg 1ndash60
MW) The costs associated with cor-
rections on side-stream compres-
sor applicationsmdashany repair
inefficient operation and power
lossesmdashwould be very high Fur-
ther compressors with side-streams
are usually sensitive and difficult
machines to operate In particular
performance curves (performance
pressures efficiency etc) are sen-
sitive to suction inlet conditionsside-stream inlet conditions vol-
ume flow ratio (side-stream vol-
ume to core-flow volume) and side-stream losses
Compressors with side-stream often perform far below
expectations The main reason is that side-stream compres-
sors are different than conventional compressors (without
a side-stream) in design and operation For a compressor
with side-streams tighter tolerances in operating conditions
must be identified and applied Uncontrolled variations of
suction pressure or side-stream pressure are major prob-
lems Another major issue is the variations of the flow ratio
(side-stream flow to core-flow)
Compressor Side-Stream amp Mixing SectionIn many centrifugal compressors the portion of the side-
stream system from the flange connection to the mixing
section is similar to a compressor inlet A great challenge
is ensuring the mixing section provides circumferentially
uniform merged-flow with minimum losses This can be
achieved via effective design of the inlet configuration and
mixing section of the side-stream compressor such that
the impeller can be maintained over the whole operating
range of the compressor In many cases while there are
mixing sections provided for the machine the flows do not
completely mix before entering the impeller of the section-2
(the impeller after the mixing section) Non-uniformity at
inlet flow to the impeller is a key concern for compressor
performance
Another consideration is a compact design of the side-
stream mixing section Specifically a mixing section with
less axial length is always preferred This axial length can af-
fect the compressor rotor dynam-
ics the rotor length and over-
all compressor performance
(design cost operation and
reliability)
The side-stream exit pressure
(side-stream pressure at inlet
of the mixing section) is mainly
a function of the side-stream
flow velocity and the pres-
sure in the previous section of
the compressor Conversely the side-
stream flange pressure can depend on
side-stream flow velocity and section-1
exit conditions Therefore the side-stream
inlet flange volume flow is a function of theflange pressure compressibility (at that
pressure and temperature) and mass flow
Some engineers assume that the side-stream flange pres-
sure is equal to the inlet pressure of the first impeller of the
section-2 This is not true The mixed total pressure can be
estimated on a mass-averaged basis using side-stream total
pressure and return channel exit (section-1) total pressure
In some designs because of the lower static pressure at
the side-stream exit the total pressure at the return channel
exit is lower even though the velocity upstream is roughly
matched for both streams The pressure usually increased
at the returned channel but it can be reduced again at the
side-stream exit While simple in nature this can have an
impact on the prediction of pressure at the side-stream exit
and overall mixing section performance Based on basic flow
principles it was usually assumed that the static pressure
was equal between both flow streams at the mixing location
While this assumption might be used in rough calculations
the accurate simulations have shown this assumption is not
true In fact there are some points (for instance the shroud
wall at the exit of the return channel and the hub wall at
the exit of the side-stream) where this assumption is true
However this is not valid for all locations There are pressure
changes that occur from a side-stream flange to the inlet
of the next section (section-2) which depend on different
factors The first factor is the frictional losses due to side-
stream geometry from side-stream flange to plenum mix-
ing section etc The other factors are pressure changes due
to local curvature and geometry details of mixing section
Another consideration is the operation of a compressor
with side-stream at part-load The performance of the side-
wwwflowcontrolnetworkcom January 2015 25
Figure 1 An example of a centrifugalcompressor with side-stream
COURTESY SIEMENS
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 29456 January 2015
Flow Control Magazine
|
y
g
stream path the mixing section and
the downstream impellers when ma-
chine is operated at part-load or even
off-design operating flows will result
in additional compressor performance
problems In such a case both veloc-
ity profiles and pressure variations in
various parts (side-stream path mixing
section etc) will be different resulting
in complicated flow patterns and com-
plex aerodynamics behaviors
Side-Stream CompressorSectional Performance
Typically vendor-supplied compressor
performance curves reflect flange-to-flange performance because that is
what the plant engineers need to
evaluate the proper operation of their
system (for example from suction to
side-stream and from side-stream to
discharge) In many cases compres-
sor vendors also provide the over-
all compressor performance curves
and performance curves for section-1
(from suction to side-stream) and sec-
tion-2 (from side-stream to discharge)
Flange-to-flange data if not interpret-
ed properly can lead to false conclu-
sions about the relative performance
of individual sections of a compression
system For example if side-stream
losses from the flange to mixing sec-
tion are attributed to the downstream
section (section-2) it will cause the
downstream section (section-2) to
appear low in performance while the
upstream section (section-1) will show
high performance levels
An important behavior to con-
sider is when the actual side-stream
pressure is different than the rated
side-stream pressure When the side-
stream pressure is slightly higher than
the outlet pressure of the section-1
it (section-1) shows a relatively higher
performance compared to the real sec-
tion-1 performance In some cases
the performance of section-1 could be
considerably higher than section-2 In
other words when performance is de-
termined flange to flange the higher
flange pressure is seen as extra ldquopseu-
dordquo work done by the section (since this
is an inconsistent thermodynamic vol-
ume) resulting in a relatively high sec-
tional efficiency (section-1 shows a rel-
atively high efficiency) This is the case
for many compressors with side-stream
because the whole system is designed
(or specifically the side-stream location
is selected) in a way aimed at main-
taining the real side-stream pressure(side-stream inlet) above the section-1
outlet pressure because if the real side-
stream pressure becomes lower than
the section-1 outlet pressure the flow
may (theoretically) reverse
This is particularly important when
the side-stream mass flow is much
lower than the mass flow of core-flow
The above-mentioned reasons explain
why in many simulations calcula-
tions and performance reports related
to compressors with side-stream the
section-1 shows a relatively good ef-
ficiency and section-2 appears low in
efficiency
When the side-stream pressure is
slightly lower than the outlet pressure
of the section-1 the section-1 might
show a relatively lower performance
compared to section-2 This could oc-
cur in some recycle services where the
side-stream is actually a recycle flow
with a mass flow around two to five
times the core-flow The side-stream
(recycle) flow is returned from down-
stream of the compressor to be slightly
compressed and recycled to the down-
stream Such a recycled side-stream
compressor can present unique chal-
lenges for design and operation This
kind of machine usually needs very
special operating procedures and very
fine adjustments regarding operating
pressures and flows
Side-Stream Compressor
Performance amp Operation An important consideration is the sen-
sitivity of compressor overall perfor-
mance curve and sectional perfor-
mance curves to the flow ratio (ratio
of side-stream flow to core-flow) and
to the inlet conditions Variations in
the flow and pressure of the main
suction and side-stream inlet should
be controlled within tight tolerances
For compressors with side-stream the ASME PTC-10 code stipulates limits on
flow ratio (side-stream volume to core-
flow volume) The acceptable variation
in volume flow ratio in a compressor
with a side-stream is +-5 percent as
per ASME PTC code The requested
side-stream pressure tolerance is not
usually specified in compressor codes
but it should be around +- 2 percent
(or sometimes +- 25 percent)
Variance in flow ratio impacts the
velocity levels where the two streams
merge Significant variation in the ve-
locity profile upstream of the impeller
changes the incidence on the blade
leading edge of the following impel-
ler This change in incidence leads to a
change in sectional performance over-
all compressor performance and train
efficiency
If the flow ratio is varied between 95
percent and 105 percent (tolerances
specified in the ASME PTC-10 code)
the flange pressure changes accord-
ingly resulting in a change in the sec-
tional performance and overall perfor-
mance The sectional efficiency varies
sometimes more than +- 4 percent
This variance reduces as the flow is de-
creased toward surge However as the
flow is increased toward overload the
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3045wwwflowcontrolnetworkcom January 2015 27
variance increases up to higher values
(even in some cases three to five times
compared to variations near the surge
zone) For example in a case study
for a compressor with side-streams a
+- 5 percent variation in flow ratio and
associated changes (pressures losses
etc) the sectional efficiency reduced by
approximately 34 percent at the rated
flow at allowable operating points at
the end of curve (near the overload
ie choke) efficiency reduced by ap-
proximately 55 percent These results
show that the variation in sectional
performance and overall performance
due to flow ratio is highest at operat-ing points near the overload and low-
est at operating points near the surge
For compressors which work most of
the time at high flow (flow higher than
rated flow and discharge pressure low-
er than rated pressure) the effects of
flow ratio deviations (and subsequently
efficiency reduction) would be higher
than compressors working on the left-
hand side of curve (say with sufficient
margins near the surge)
In the compressor codes (such as
API 617) the compressor power varia-
tions should be maintained below 4
percent However in some applica-
tions clients require tighter tolerances
on the consumed power sometimes
below 2 percent (or even below 15
percent) Some studies suggest while
+- 5 percent of volume flow ratio is
suitable for performance test as per
ASME PTC-10 code some plants re-
quire tighter control on the consumed
power and compressor performance
(lower limits on the efficiency) the tol-
erances on the volume flow ratio could
be tighter than ASME PTC code In this
regard +- 4 percent tolerance can be
suggested on the volume flow ratio (ra-
tio of side-stream flow to core-flow) of
compressors with side-streams
Based on operational experiences
acceptable variations in volume flow
ratio and inlet pressures (suction inlet
and side-stream inlet) of a compressor
with side-streams are +- 4 percent
and +- 2 percent respectively
Another important consideration is
the required adjustments for the flow
ratio (side-stream flow to core-flow)
Compressors with side-stream usually
require fixed side-stream flange pres-
sures For a compressor with some variations in operation conditions (even
small changes) it is not usually pos-
sible to achieve optimum operation by
keeping the flow ratio (side-stream to
core-flow) constant The flow ratio has
to be adjusted according to the inlet
flow at which the machine is operating
in order to get the required correspond-
ing side-stream flange pressure
Thermal changes have also been
known to cause some instability in
centrifugal compressors An example is
the thermal-induced change of resid-
ual unbalance For compressors with
side-streams which feature tempera-
ture differences between core-flow and
side-stream flow the thermal behav-
ior of the compressor is usually more
complex and requires more attention
Heavy Gas ChallengeHeavy gases (such as heavy hydrocar-
bon gases eg propane propylene
MTBE (Methyl Tertiary Butyl Ether))
have very low gas sonic velocities that
produce high Mach numbers in the
aerodynamic flow paths For these
services because of high Mach num-
ber high flow coefficient stages have
very narrow flow maps characterized
by limited surge and choke margins
Compressors with side-streams in
these services present great challeng-
es This is to say the side-streams and
associated mixing further complicate
design operation and performance
prediction because the pressure tem-
perature and flow conditions at each
one of these side-streams as well
as at the exit of the machine require
stringent tolerances to optimize the
overall efficiency and performance
As such it is important to accuratelymodel design operate and moni-
tor performance characteristics of any
impellers diffusers return channels
and generally all flow-path components
in a compressor with side-stream FC
Amin Almasi
is a senior rotating
machine consultant
in Australia He is
a chartered profes- sional engineer of
Engineers Australia
(MIEAust CPEng ndash
Mechanical) and
IMechE (CEng MIMechE) holds
bachelorrsquos and masterrsquos degrees
in Mechanical Engineering and is
a registered professional engineer
in Queensland He specializes in
rotating machines including cen-
trifugal screw and reciprocating
compressors gas turbines steamturbines engines pumps subsea
offshore rotating machines LNG
units condition monitoring and reli-
ability Mr Almasi is an active mem-
ber of Engineers Australia IMechE
ASME and SPE He can be reached
at aminalmasiymailcom
Amin Almasi
Compressor | Gas Flow | Performance Curve | Side-Stream Flow
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3145
The pressure in the stuffing box
containing the packing can be estimat-
ed by the following equation
SBP = [Discharge ndash Suction] 3 + Suction
Pressure at the bottom of the stuff-
ing box will be higher than the suction
pressure but considerably lower than
the discharge pressure It should be
noted this calculation will yield a con-
servative estimate of stuffing box pres-
sure that can be further reduced by
pump design
A hole in the stuffing box serves as
a port for injecting clean fluid that cir-
culates around a lantern ring aligned
under the flush port The fluid flushes
solids back into the process to protect
the packing from abrasive wear If the
clean fluid is injected at a pressure ex-
ceeding that at the bottom of the stuff-
ing box some of it will leak back into
the process and some will leak out to
the atmosphere Recommended flush
injection pressure is 15ndash30 PSI (1ndash2
Bar) greater than the pressure at the
bottom of the stuffing box
Fluid injection is also used to lubri-
cate and cool dry-running packing that
is subject to frictional heat and to pre-
vent air from entering the pump which
reduces flow and operating efficiency
Centrifugal pumps utilize three
types of impellersmdashopen semi-open
and closed (Figures 2 3 amp 4) Open
designs prevent fluids with large solids
from clogging the impellers but at theexpense of pump efficiency Backing
plates on semi-open designs serve to
trap the fluid for more efficient opera-
tion Closed impellers are for use with
clean fluids since solids could ac-
cumulate in the eye which would re-
quire tearing down the pump to remove
them
Single-Stage CentrifugalPumpsSingle-stage centrifugal pumps typi-
cally have good bearing support of the
shaft with few run-out or ldquowhiprdquo prob-
lems However in some cases they
are subject to cavitation This occurs
in the eye of the impeller where the
fluid is under vacuum If the pressure
is low enough it will cause the material
to vaporize forming air or water vapor
bubbles As the fluid passes through
How Pumping Systems Design Affects Sealing Performance
By Chris Boss
8 January 2015
Flow Control Magazine
|
Understanding how different types of pump designs impact
sealing is critical to optimizing efficiency safety and lon-
gevity of the sealing system Used for a wide variety of media
including clear fluids solutions and slurries single-stage
centrifugal pumps are one of the most common
types (Figure 1) Fluid drawn into these pumps
enters the eye of an impeller that spins itto the outside of its container
or volute building pressure as
it moves toward discharge
Some of this fluid will work
its way behind the impeller
where it must be sealed with
compression packing or a
mechanical seal
Figure 1
Figure 2 Figure 3 Figure 4
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3245
the pump under increasing pressure
these bubbles implode sending shock
and vibration through the impeller
adversely affecting the seal This phe-
nomenon can be mitigated by running
the pump at slower speed and higher
pressure at the suction end to prevent
air from entering the fluid
Double-Ended Split-CasePumpsOperating on the same centrifugal prin-
ciple but slightly different geometry are
double-ended split-case pumps (Figure
5) Fluid enters both ends of the pump
and is directed into the eye of an impel-ler which spins it out of the volute to
discharge Packing is installed on both
the shaft and bearing ends so the stuff-
ing box is exposed only to suction pres-
sure which is usually quite low
Axial Flow Pumps Axial flow pumps operate like hydro
turbines in reverse whereby a propeller
(or axial impeller) pushes the fluid to
discharge (Figure 6)
Since the stuffing box is located
downstream of the propeller at the dis-
charge end of the pump the packing is
exposed to the full discharge pressure
Vertical PumpsVertical turbine pumps are typically
flange-mounted on a floor extending
downward into a water-filled sump
hole (Figure 7) Available as single- or
multi-stage pumps they feature an
impeller or series of impellers rotated
simultaneously by a single shaft The
impellers increase the pressure of the
upward flow subjecting the stuffing box
to full discharge pressure
Vertical pumps can be quite long so
inadequate bearing support can cause
the shaft to run out This can induce
undesirable lateral motion on the pack-
ing Worse the packing may be forced
to serve both as a bearing and a seal To
withstand these conditions the packing
should be resilient elastic and resistant
to deformation These properties rule
out packing such as graphite foil in favor
of fiber-based materials
Multi-Stage PumpsMulti-stage pumps are used for high-
pressure applications such as feeding
the boilers in steam-powered generating
plants Stuffing box pressure can vary
with pump design and number of stag-
es Designed for clean fluids and high
operating speeds these pumps typically
have high- and low-pressure ends with ahydraulic pressure equalization line run-
ning between the stuffing boxes
Like vertical pumps multi-stage
pumps feature a series of impellers to
build fluid discharge pressure In the
case of the six-stage pump pictured in
Figure 8 fluid enters at the drive end
where a stuffing box is exposed to suc-
tion pressure Channeled from one
impeller to the next through the pump
casting the fluid can reach extremely
high pressures at discharge
A second stuffing box located at the
bearing end is exposed to an intermedi-
ate pressure from the third impeller This
pressure is greater than the suction pres-
sure but much less than the discharge
pressure which can reach 2000 PSI
Fortunately the stuffing boxes in
these pumps are not exposed to dis-
charge pressures and typically see be-
low 500 PSI which is within the range
of some packing materials
wwwflowcontrolnetworkcom January 2015 29
Figure 5
Figure 6
Figure 7
Figure 8
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 33450 January 2015
Flow Control Magazine
| Gear PumpsPositive-displacement or gear pumps
operate on a different principle than
centrifugal pumps In external gear
pumps the fluid flows around the out-
side of the gears the intermeshing
of which forces it through the pump
to discharge (Figure 9) This design
makes these pumps particularly suit-
able for use with highly viscous fluids
such as resins emulsions syrups and
adhesives As such they are used for
transfer or metering applications
It should be noted gear pumps will
continue to displace fluid as long as
their shafts are turning which can pose
a problem if a clog occurs at the dis-
charge The resulting buildup of pres-
sure can blow out seals and damage
the pump Therefore most gear pumps
have pressure relief valves to divert
fluid back to the suction side for re-
circulation through the pump Internal
gear pumps operate slightly differently
but also have pressure relief valves to
prevent damage from excessive pres-
sure (Figure 10) In both external and
internal gear pumps the maximum
stuffing box pressure is determined by
these valves
Other rotating equipment includes
mixersagitators which are similar to
pumps in terms of the speeds to which
the packing is exposed There are ba-
sically three types of mixersagitators
top- bottom- and side-entry Top-entry
models are subject to the same con-
cerns about shaft run-out ldquowhiprdquo and
lateral forces on the paddles that are
encountered in some vertical pumps
Although some fluid may splash onto
the packing these mixers basically run
dry so the packing must have the abil-
ity to dissipate the resulting frictional
heat
In bottom-entry mixers the packing
is always exposed to fluid and may also
be exposed to solids requiring abra-
sion-resistance If the seal fails the en-
tire contents of the tank will eventually
drain out onto the bearings the floor
and other components under the stuff-
ing box
The packing in side-entry mixers may
be fully or intermittently exposed to flu-
id as well as side loading and vibration
Aside from media temperature
speed and other application variables
the configurations and operating prin-
ciples of rotary-type pumps exert differ-
ent forces on the seals used to keep
them from leaking These forces can
spell the difference between accept-
able seal performance and failure
Understanding these differences has
important implications that should be
taken into account to assure proper
sealing selection for long-term trou-
ble-free performance FC
wwwgarlockcom
Chris Boss is
a senior applica-
tions engineer for
Garlock Sealing
Technologies in
Palmyra NY He
has held various
positions in produc-
tion engineering
product development and applica-
tions engineering for the companyrsquos
compression packing division He
is a BSME graduate of the State
University of New York at Buffalo Mr
Boss can be reached at 800 448-
6688 or chrisbossgarlockcom
Chris Boss
Cavitation | Centrifugal Pump | Pump Packing | Sealing System
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Figure 9
Figure 10
Aside from media temperature speed and
other application variables the configurations
and operating principles of rotary-type
pumps exert different forces on the seals used
to keep them from leaking These forces can
spell the difference between acceptable seal
performance and failure
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3445
NS IDERNDUSTRIAL AUTOMATION + PROCESS CONTROL
WANT
INFORMATION
ON THE
automationindustry
SUBSCRIBE NOW at wwwiainsidercouk
Published by Spitzer and Boyes LLC Write in 15 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3545
Frost says the push from developing
economies is important as the market
is technologically mature and seeing
restricted growth in developed econo-
mies This is particularly true in Europe
and North America where recent finan-
cial insta-
bility has
reduced capital expenditure across end-
user industries
Bill Moore senior vice president of
sales development and channel man-
agement for global bearings manufac-
turer SKF says ldquosmartrdquo products and
the expansion of robust reliability pro-
grams are helping to drive new invest-
ment particularly in developed coun-
tries where the cost to compete is
high Frost says the magnitude of
the existing global installed base will
strengthen the need for replacement
and upgrades adding to market de-
mand as well
Frost says despite the potential
in developing economies the focus
on price as a product differentiator
may lead to intense price pressures
among manufacturers and bring down
the value of the overall market in the
short term The growing trend among
consumers to choose low-cost Chinese
imports will complicate this challenge
As price and quality become stan-
dardized across the globe customers
will base more of their purchasing deci-
sions on value-added services accord-
ing to Frost This will push manufactur-
ers to create more maintenance-free
solutions such as lubrication-free
bearings that offer end-users savings
on service and replacement costs and
reduce downtimeldquoOffering a complete line of prod-
ucts with comprehensive services will
be another feather in the cap of ven-
dors looking to widen their consumer
baserdquo notes Frost Industrial Automa-
tion and Process Control Research
Analyst Guru Mahesh
Moore says the trend of outsourcing
manufacturing to regions where labor
and production costs are favorable is
becoming less of a factor
ldquoThe days when cheap labor made
a significant difference in where a prod-
uct is manufactured mdash particularly high
value-added products or high weight
and bulk products mdash are coming to
an end as the cost of transportation
storage and inventory balance out the
benefits of production costs where la-
bor is a smaller percentage of the cost
of manufacturingrdquo Moore says ldquoLocal
manufacturing development will indeed
come to developing countries as their
ability to create markets that generate
economies of scale that support local
production is a clear trend and one that
all manufacturers will pay attention tordquo
Moore says that development of
maintenance-free or predictive tech-
nologies and products will be a sig-
nificant advantage to everyone in the
Bearing amp Coupling Manufacturers Focus
onDEVELOPING Economies
amp EFFICIENCY InnovationBy Amy W Richardson
2 January 2015
Flow Control Magazine
|
gy
Anew study from Frost amp Sullivan (wwwfrostcom) fore-
casts steady growth for the overall bearings and couplings
market based on rapid industrial development in high-growth
regions Specifically Frost predicts development in Mexico
Indonesia Nigeria Turkey Brazil Russia India and Chinawill help boost the bearings amp couplings market from $2206
billion in 2013 to an estimated $2676 billion in 2018
The development of maintenance-freeor predictive technologies will helpboost growth in the bearings market For example SKF is developing products that will automatically notifyusers when a bearing or mechanicalrotating component is approachingthe end of its useful life Pictured hereis an SKF Microlog analyzer a por- table condition monitoring tool
COURTESY SKF
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
improved productivity through simplified solutions The powerful technology and tools ensure repeatable
reliable accurate measurements Easier access to process data allows for better troubleshooting process
optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
For daily product notes visit the lsquoFeatured Productsrsquo section flowcontrolnetworkcom
ON THE WEB
1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3845
FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
and benefits as well as grids of
instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
services provided for the
mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
Brought to you by Beamex
Your Source For Fluid Handling Videos
Go towwwflowcontrolnetworkcomfreeinfo
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Select advertisements thatinterest you
Enter your email amp clickldquoSubmit Requestrdquo
1
2
3
4
PRODUCT
INFORMATION
ONLINE
Follow these 4 steps to receive freeproduct information from suppliers
FREE
FEATURED VIDEO How to Calibrate aPressure Measurement Loop
For more information about FlowTube
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4245
THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
Name ________________________________________________________________
Title _________________________________________________________________
Company _____________________________________________________________
AddressCityStateZip __________________________________________________
______________________________________________________________________
Phone ________________________________________________________________
E-Mail ________________________________________________________________
One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545
![Page 11: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/11.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1145
HE OUTLOOK | News amp Notes
1 ISO15848 ldquoMeasurement test and qualification proce-
dures for fugitive emissionsrdquo
a Part I ndash ldquoClassification system and qualification proce-dures for type testing of valvesrdquo
b Part II ndash ldquoProduction acceptance test of valvesrdquo
2 API 622 ldquoType Testing of Process Valve Packing for Fugitive
Emissionsrdquo
3 End-user defined fugitive emission reduction requirements
Key aspects of valve testing per API 624 include
The standard covers rising and rising-rotating stem
valves up to 24rdquo diameter
Class 1500 valves are not covered
The test medium is methane
310 test cycles are required with three thermal cycles Temperature application range is from -29 C to 538 C
with last cycle 10 cycles user-defined (can be -45 C)
Re-tightening of gland bolts is not permitted during test
Valve stem test orientation is vertical
Several valves must be tested to achieve API 624 com-
pliance Similar industry principles applied to test valves
qualify two nominal sizes smaller one size larger and one
pressure class below
Allowable leakage is 100 PPM maximum
Gate and globe valves need to be tested separately
For example Gate Valves per API602 four tests API600
eight tests (up to 20rdquo diameter) API 603 eight tests andfor Globe Valves per API 602 four tests
Test valves should be production valves not specially
manufactured test valves
As a result of the release of API 624 testing companies have
been gearing up for an increase in the number and size of
test valves and new test houses are coming to market Withthis in mind implementation of API 624 needs to be carefully
monitored and claims from valve manufacturers should be
validated by requesting to view test results Important factors
to be mindful of include
Number of cycles on some valves could be detrimental
to packing as certain smaller size valves donrsquot come with
grease ports to keep the stem lubricated all of the time
Test failures of valve stem threads yokes and glands
Grease traps into packing and causes leakage
At higher temperatures a few greases create volatile
organic compound and burn off
Testing in vertical generates more heat in yoke area
Certain challenges need a good testing company that has
experience in testing on fugitive emissions and provides
guidelines to manufacturers in terms of use of packing valve
grease testing requirements etc
A preliminary survey was conducted with end-users regard-
ing current utilization and application of API 624 For a sum-
mary of responses from this survey visit flwctrlcom1oWijWz
Gobind Khiani PEng is with Fluor Canada Ltd Khiani has
spent 20-plus years in the energy and power business and 10-
plus years in the Western Canadian oil and gas industry Hecan be reached at 403 850-6982 or gobindkhianifluorcom
Valve Standards UpdateEnd-users ramp up compliance efforts for API 624
as new specifications emerge on the horizon
8 | January 2015
Flow Control Magazine
By Gobind Khiani
In the May 2014 issue of Flow Control (page
16) the new standard API 624 ldquoType Testing
of Rising Stem Valves Equipped with Graphite
Packing for Fugitive Emissions First Editionrdquo was
addressed This standard which was published
and put into effect in February 2014 estab-
lishes guidelines for testing industrial valves for
emissions compliance Since the publication ofthe May article further requests from industry
have spurred the creation of another specifi-
cation API 641 ldquoType Testing of Quarter-Turn
Valvesrdquo and an API ldquoPiping and Valvesrdquo commit-
tee has been formed Regulators and end-users
are also working on
1992 1998 2003 2008 2013 2020
4
35
3
25
2
15
1
05
0
M i l l i o n o f
t o n n e s y e a r Will API 624
have a stepeffect in reducing
fugitiveemissions
Global valve fugitive emissions
End User response at best
End User response actual
S O U R C E G O B I N D K
H I A N I
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1245
Intelligent Features to Boost Global WaterDesalination Pumps Market
The Global Water Desalination
Pumps Market is expected to grow
at a CAGR of 77 percent from 2015 to
2019 according to a new report from
TechNavio (wwwtechnaviocom)
The report shows demand for water
treatment has increased significantly in
developing countries where fresh wa-
ter resources can be scarce Providing
clean and potable water to huge popu-
lations has become a priority which is
pushing the demand for water desalina-tion pumps in the market according to
TechNavio
The report emphasizes the emer-
gence of intelligent pump systems as
a major driver of market growth In-
telligent pumps possess the ability to
regulate flow and pressure and these
systems can automatically adjust to
process and pump system changes
ldquoIntelligent pump systems are be-
ing adopted by many manufacturers
because of the high level of fault toler-
ance ability which leads to a significant
reduction in the total cost of owner-
shiprdquo said Faisal Ghaus vice president
of TechNavio in a news release ldquoThe
adoption of these systems will also
help industries comply with current Eu-
ropean Union regulations in relation toreduction in energy consumptionrdquo
The growing demand for clean wa-
ter worldwide will continue to augment
the demand for water desalination sys-
tems which will propel the Global Water
Desalination Pumps Market during the
forecast period
trendlines
wwwflowcontrolnetworkcom January 2015 | 9
Write in 8 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
Intelligent pump sys-tems are being adopt-
ed by many manufac-
turers because of the
high level of fault tol-
erance ability which
leads to a significant
reduction in the total
cost of ownership
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1345
HE OUTLOOK | News amp Notes
10 | January 2015
Flow Control Magazine
Hydraulic Fracturing WaterTreatment amp Reuse Expected to Soar
Wastewater treatment spending for
hydraulic fracturing is expected to
grow almost three-fold from $138 mil-
lion in 2014 to $357 million in 2020 in
the US according to a new report from
Bluefield Research
The US hydraulic fracturing industry
consumes over 1 billion barrels of wa-
ter annually producing 450ndash500 mil-
lion barrels of contaminated water for
disposal with only about 14 percent
treated and reused Bluefield cites watersupplies increasingly at risk tighter regu-
lations emerging in key states and costs
of disposal on the rise as factors con-
tributing to the substantial rise in water
treatment and reuse which is expected
to account for 27 percent of total pro-
duced and flowback water by 2020
Overall the US hydraulic fracturing
industry will spend $638 billion in 2014
on water management Water transport
and disposal costs will account for 66
percent of the total water managementspent this year with treatment compris-
ing roughly 2 percent
Bluefield reports water scarcity in
Western US states has had little im-
pact to date on fracturing water supply
but that is likely to change if droughts
persist Meanwhile state regulators are
beginning to tighten control of produced
water disposal In Pennsylvania where
policymakers in 2010 placed discharge
limits on wastewater from unconven-
tional oil amp gas operations statewide
treatment and reuse rates for the Mar-
cellus jumped to 90 percent in 2014
The increasing cost of transport and
injecting water into wells mdash now ac-
counting for 66 percent of water servicesspending mdash and the improving cost
structures of treatment provide another
driver of reuse Bluefield reports Well
operators that employ treatment and re-
use solutions spend on average $880
per barrel of water used compared to
$1020 per barrel of water trucked and
injected into wells although cost com-
parisons are site specific
ldquoFracking has been the Wild West for
the US water industryrdquo said Reese Tis-
dale president of Bluefield Research ina prepared statement ldquoThere are three
reasons for this first there has been
an explosive build-out of fracking well
installations now surpassing 126000
Second there has been a lack of clear
regulation on water management in key
markets And third there is not a one-
size-fits-all treatment solution for frack-
ing meaning solutions providers have
had to ascend a steep learning curve
to treat the variable wastewaters that a
single well is capable of producingrdquo
Tisdale notes that these inhibitors
while still acute are beginning to take on
a new form This is partially due to signifi-
cant gains in water management experi-
ence realized adoption of more efficientwater management strategies among
well operators and the emergence of
new policy mechanisms from regulators
that are playing catch-up with the fast-
moving hydraulic fracturing industry
trendlines
Treatment2
Disposal
6
Supply10
Storage22
Transport60
US $638Billion
S O U R C E B L U E F I E L D R
E S E A R C H
Write in 23 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
Industry-Leading
Warranties
Temperature Measurement Solutions
bull Probe type industrial RTDsbull Electronic temperature switchtransmitter bull Vapor-actuated remote thermometersbull Digital temperature indicatorsbull Platinum resistance temperature transmitterbull Compact OEM temperature transmitter bull Industrial amp instrument type bimetal thermometersbull Thermowells
1010 West Bagley Road I Berea Ohio 44017 I P 4402430888 I F 4402433472wwwnoshokcom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1445
New Technique Could ReduceEnergy Required for Oil Refinement
UK scientists have developed a
technique they say has the poten-
tial to dramatically reduce the amount
of energy required for the refinement
of crude oil
Professor Martin Schroumlder and Dr
Sihai Yang from The University of Not-
tingham (wwwnottinghamacuk ) have
led a multi-disciplinary team of scien-
tists from Nottingham the Science and
Technology Facilities Councilrsquos (STFC)
ISIS Neutron Facility Oak Ridge Na-tional Laboratory and Diamond Light
Source to discover a porous material
that works like a chemical sponge to
separate a number of important gases
from mixtures generated during crude
oil refinement
According to a news release from
The University of Nottingham the ex-
isting industrial process uses ldquohuge
amounts of energy to separate and pu-
rify these gases so the new technique
has the potential to revolutionize the oil
industry by significantly reducing car-
bon emissions and making the process
more environmentally friendlyrdquo
Commercially UsefulCrude oil is a raw material that is
refined to produce fuel for cars toheat homes and to create polymers
and other useful materials It is made
up of a complex mixture of hydro-
carbons (chemical compounds that
contain only hydrogen and carbon) of
which certain components are espe-
cially commercially useful
One industrial process used to
achieve hydrocarbon separation is
called ldquocryogenic distillationrdquo which is
widely used worldwide and uses vast
amounts of energy to generate the high
pressures and cryogenic temperatures
required to ensure efficient separation
research amp development
wwwflowcontrolnetworkcom January 2015 | 11
PLASTIC CONTROL VALVES FORALL YOUR CORROSIVE APPLICATIONS
PO Box 938 bull Angleton TX 77516Tel (979) 849-8266 bull wwwcollinsinstcom
Collins plastic control valves are
highly responsive control valves
designed for use with corrosive
media andor corrosive atmos-
pheres
Collins valves feature all-plastic
construction with bodies in PVDF
PP PVC and Halar in various body
styles from 12 - 2 with Globe
Angle or Corner configurations and
many trim sizes and materials
Valves may be furnished without
positioner for ON-OFF applications
Call for more information on our
plastic control valves
Write in 9 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1545
of hydrocarbon mixtures into pure components
However researchers say an innovative solution may
have come in the form of a novel chemical sponge This
porous material a metal-organic framework was devel-
oped by the same team at Nottingham just two years ago
Now in research published in Nature Chemistry for the
first time scientists have proven that it can be used toseparate hydrocarbon mixtures without the need for high
process pressures or very low process temperatures
Reusable MaterialsMade from cheap organic materials aluminum nitrate
salt and water the porous material called NOTT-300 is
able to adsorb different gases found in mixtures of hydro-
carbons at different rates making it possible to sepa-
rate them and extract the most useful ones NOTT-300
requires less energy to function than existing methods
as it operates at ambient temperatures and normal pres-
sures researchers say The gases that are adsorbed intoNOTT-300 can be removed without a significant energy
input and therefore the material can be easily reused
The team of scientists from Nottingham used Diamond
the UKrsquos synchrotron science facility as well as STFCrsquos
ISIS Neutron Facility and Oak Ridge National Laboratory
the UKrsquos and USArsquos world-leading neutron facilities re-
spectively to prove that the sponge works under real-life
conditions
Professor Martin Schroumlder Dean of the Faculty of Sci-
ence at Nottingham said in the news release ldquoIt is a very
important to be able to separate different hydrocarbons ef-
fectively and efficiently with low-energy consumption Po-rous solids such as the metal-organic framework system
studied here represent important materials for the future
development of low-energy separation technologies We
are most grateful to our collaborators at ISIS Neutron Fa-
cility Oak Ridge National Laboratory and Diamond Light
Source in bringing this work to fruitionrdquo
Significant Impact on Oil IndustryDr Sihai Yang the winner of Diamond Young Scientist
and BTM Willis Prize is a Senior Research Fellow at
Nottingham He led the project together with Professor
Martin Schroumlder Yang said ldquoWith the help of advancedcentral facilities like Diamond ISIS and ORNL we have
developed a new separation technique which can poten-
tially reduce the energy usage associated with oil petro-
leum and chemical industries which require the separa-
tion of raw hydrocarbons from crude oil
The discovery of the new material NOTT-300 could
have a significant impact on the oil industry by removing
the necessity for some energy-intensive refinement pro-
cesses researchers say
The research was funded by Engineering and Physical
Sciences Research Council (EPSRC) the European Re-
search Council (ERC) The University of Nottingham andLeverhulme Trust
12 | January 2015
Flow Control Magazine
Write in 21 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
No media contact - No risk of leaks
No process Shut-Downs for installation
No bypass needed
For hazardous area locations (FM approved)
Monitor your Total Acid Consumption
Increase your Plant Up-Time
Balance your Processes
PIOXreg S
PIOXreg S - the evolution of flow and concen-
tration measurement in acid production
Non-intrusive mass flow concen-
tration and density measurement
of aggressive media
wwwpiox-scom
wwwfleximcom
Contact us for a free trial measurement
Thank you for your votes and
making PIOXreg S a Flow Control
Awards Winner
THE OUTLOOK | News amp Notes
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1645
The ASCO trademark is registered in the US and other countries The Emerson logo is a trademark and service mark of Emerson Electric Co copy 2014 ASCO Valve Inc
1-800-972-ASCO (2726) | e-mail info-valveascocom | wwwascovalvecomSpoolValve
Now get spool valves with industry-leading ASCO solenoid technology built in
Delivering unmatched performance and durability our compact new valves are
perfect fits for all your onshore near-shore or offshore upstream control panels A
range of easily configured features and options includes superior temperature and
pressure ratings plus low-power models The industryrsquos toughest testing ensures
every rugged stainless steel valve meets or exceeds specifications Plus we design
and support every spool valve we make Ask for ASCO the ultra-reliable choice for oil
and gas control panels
These new spool valves will fit right in
Write in 22 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 174514 | January 2015 Flow Control Magazine
PPLICATIONS CORNER | Process Instrumentation
This is the final article in a series based on the troubleshoot-
ing of a mysterious unit shutdown due to flowmeter perfor-
mance problems
If yoursquove followed this column for most of 2014 you know
that what should have been a liquid ammonia stream to the
feed plant became problematic due to the occurrence of
bubbles of ammonia gas These bubbles caused an ultrasonic
flowmeter in a unit to indicate zero flow and caused the reactor
to scram (shut down) under warm operating conditions The source of the bubbles was traced back to the pres-
sure drop associated with a control valve located at the
exit of the liquid ammonia tank farm
This issue was resolved by identifying the problem
and fixing it at its source This was a pragmatic ap-
proach at the time (early 1980s) given the operation
of the cooling system in the unit and the limited selec-
tion of applicable flowmeter technologies
By the early 1990s changes were implemented that elim-
inated all process cooling requirementsmdashexcept for the small
jacketed cooler upstream of the liquid ammonia flowmeter In
other words after these changes the entire cooling system
would be operated and maintained to cool a few meters of
one small ammonia pipe Coincidently at about the same
time Coriolis mass flowmeters became more mature and
could reasonably measure the mass flow of liquid streams
with homogeneous low levels of vapor
The convergence of these two events resulted in another
approach to the problem that was not available in the early
1980smdashie install a Coriolis flowmeter that could operate in
the presence of bubbles The purchase and installation of a
Coriolis mass flowmeter was given high priority given its im-pact on unit operation economics and safety (by eliminating
the ldquomidget-makerrdquo (see March 2014 page 14))
Plant requirements and the technology that can meet
plant needs keep changing An excellent solution today can
become outdated in just a few years However there are few
substitutes for understanding fundamentals when addressing
a problem In other words there can be more than one way
to skin a cat FC
wwwspitzerandboyescom
Problem Solved AgainA Coriolis mass flowmeter provides a better solution
F o r B e t t e r P i p i ng S y s t e m P e r f o r m a nc e hellipFor Better Piping System Performancehellip
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bull Rugged thermoplasticshandle corrosive andultra-pure chemicaltreatments
bull Constant pressure enhances
pump performancebull Prevents overpressure in
piping system
bull Wide range of pressuresettings
bull PTFE shaft and diaphragm designs
bull 1 4rdquo - 3rdquo sizes in PVC CPVC PVDFPolypro and PTFE
bull First State approved
thermoplastic valve for
anti-siphon applications
Write in 10 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
David W Spitzer
Ammonia Gas | Coriolis Flowmeter | David W Spitzer | Scram | Troubleshooting
FLOWSTREAM Find related content flowcontrolnetworkcom
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and Boyes
LLC offering engineering seminars strategic marketingconsulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer can be reached at 845 623-
1830 or at wwwspitzerandboyescom
The purchase and installation of a
Coriolis mass flowmeter was given
high priority given its impact on unit
operation economics and safetyldquordquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1845
Smart Valve Positioner
Beyond Control The NEW Research Controlreg SRD positioner does
everything you expect any valve positioner to do
plus more The SRDrsquos comprehensive diagnostics tool
continuously monitors for fugitive emissions delivers
real-time performance statistics and facilitates both
proactive and reactive process management Available
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compatible with Research Control valves and most other
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Visit wwwbadgermetercomSmart-Valve-Positioners or
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1945
Process improvements to increase yield or cut manufactur-
ing costs typically require enhanced process control but the
installed base of measurement instrumentation in a process
plant may simply be unable to facilitate improvements because
of age inadequate performance or unreliability Maintenance
cost and unscheduled process downtime for an aging process
plant can be very damaging to the balance sheet Upgrading
to new more accurate and more reliable instrumentation can
be prohibitively expensive New plant construction must alsomaintain a focus on optimizing costs for the process control
infrastructure The budget approval decision for new plant
construction must weigh such costs against projected market
conditions for the products that the plant is intended to manu-facture In todayrsquos volatile global marketplace return on invest-
ment calculations for plant upgrade or new plant construction
projects may go through several iterations before the trigger is
finally pulled or indeed not pulled
This article describes advances in two-wire instrumenta-
tion specifically in relation to flowmeters that have taken
place in the past few years and the significant cost benefits
that this new technology can realize for plant builders and op-
erators in terms of capital investment and cost of ownership
The Significance of Two-Wire Loop Power
A survey involving 204 participants in the chemical indus-try across Germany Switzerland the UK Canada and the
United States (Manfred Koenig PhD KIM Ludwigshafen
Germany 2006) revealed an 87 percent preference for two-
wire instrumentation versus four-wire in process applications
and 89 percent for utilities This overwhelming preference
may stem from the fact that older process plants were built
with two-wire twisted-pair cable networks connecting all
process units and measuring instruments together in an
overall plant control scheme
However these existing cables are relatively unsophisti-
cated and incapable of supporting anything but low-energy
instrumentation that is insensitive to interference from otherelectrical sources that might be sharing the same cable con-
duit Further the low energy levels supported by these two-
wire loops are more easily rendered safe in terms of explo-
sive risk in hazardous areas containing flammable materials
Many older process plants are also likely to have a significant
installed base of flowmeters employing pre-war (pre-1945)
technology such as positive displacement (PD) turbine vari-
able area (VA or Rotameter) and differential pressure (dP)
Market data firm Flow Research Inc (wwwflowresearch
com) indicates collectively a future compound negative annual
growth rate approaching minus 3 percent to 5 percent for PD
turbine and VA flowmeter types while dP is expected to keeppace with market growth (World Market for Flowmeters 2010)
YSTEMS DESIGN | Flow Measurement
16 | January 2015
Flow Control Magazine
The Two-Wire
ADVANTAGENew wiring options enable modern instrumentsto drive cost savings in existing plant systems
By Steve Milford
Advances in two-wire instrumentation have enabled mod- ern technology to be employed to the advantage of older
plant and process systems
Some chemical manufacturing plants are
competing for survival not only externally
against other global companies but also
internally among the global facilities of theirown company Other industry sectors face
similar challenges
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2045wwwflowcontrolnetworkcom January 2015 | 17
The Need to Replace Older TechnologiesUntil the 21st century two-wire loops were only able
to support these relatively unsophisticated instruments
which convert their measurement by various means into a
4-20mA output or pulse signal to the control system The
more advanced post-war flowmeter technologies such as
Coriolis ultrasonic or electromagnetic flowmeters have
until just eight years ago required a dedicated power sup-
ply for their function in addition to the output loop and
thus a four-wire infrastructure was required as a minimum
Therefore upgrading older two-wire meter devices to moremodern four-wire technology could require significant
expenditure in terms of the installation of separate power
cables and supply modules
There was a major breakthrough in 2006 when a true
two-wire loop-powered inline liquid ultrasonic flowmeter
was introduced (Figure 1) The nature of this breakthrough
was innovation in device power management This was the
missing piece up to that point because to be a true loop-
powered device the meter had to directly provide a full 16
mA span using less than 36 mA of remaining loop current
and less than 1 Watt of electrical energy The flowmeter
operated on a single 4-20 mA HART two-wire loop wasremotely powered by a DC supply was certified Class 1 Divi-
sion 1 and could be deployed as Intrinsically Safe through
the use of an approved safety barrier
A true two-wire loop-powered Coriolis flowmeter followed
in 2011 (Figure 2) employing a new and more advanced
common electronics platform A two-wire loop-powered inline
ultrasonic flowmeter for low-pressure gas was introduced in
2012 and a second two-wire loop-powered Coriolis meter fol-
lowed in 2013 offering improved measurement performance
and an additional high-performance meter tube material
Electromagnetic and vortex flowmeters had already been
available for some years in two-wire loop-powered form butimproved performance resulted as these designs were incor-
COURTESYENDRESS+HAUSER
Figure 1 A two-wire ultrasonic flow- meter released in 2006 operated ona single 4-20 mA two-wire loop
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I I I I LL I
copy COPYRIGHT 2015 OMEGA ENGINEERING INC ALL RIGHTS RESERVED
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Prices listed are those in effect at the time of publication and are subject to change without noticePlease contact OMEGArsquos sales department for current prices
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FPD3300 SeriesStarts at
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OSXL-TIM3$999
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Positive Displacement Flow Meterfor Fuels and Oils
bull Aluminum Bodybull FKM Sealsbull Temperatures up to
80ordmC (176ordmF)bull NPT or BSP Threadsbull DIN JIS or ANSI
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Thermal Imaging CameraFor Inspection andFactory Diagnosis
Note Not for ExportUSA Only
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7232019 Flow Control January 2015
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Flow Control Magazine
porated into their new common electron-
ics platform in 2013 So all the ldquomodernrdquo
flow measurement technologies mdash that
is to say those introduced post-war mdash
have become available as two-wire loop-
powered devices with one exception
namely thermal mass (thermal disper-
sion) meters Unfortunately the power
requirements for this technology exceed
what is currently deemed possible withtwo-wire loop-power management
Payback forTechnology UpgradeConsider a 1rdquo process line
containing a liquid process
ingredient costing $1lb at a
mass flowrate of 150 lbmin-
ute We have $150minute
flowing in the line translating
to $9000hour and $72000
per eight-hour shift That cal-culates further to $360000
per five-day working week and
for a working year of 40 weeks for
example that is $144 million Assume
the existing device is a turbine flowmeter
Now imagine a two-wire loop-
powered Coriolis mass flowmeter is
installed in place of the existing meter
The line would need to be drained and
probably one process flange replaced
allowing the Coriolis to fit mechanically
in place of the turbine However thetwo-wire loop already used for carrying
the existing meterrsquos flow signal to the
control room can be used unaltered
for the complete electrical installation
aspects of the Coriolis flowmeter
The upside of the change is signifi-
cant and clear cut Assuming the exist-
ing meter measurement uncertainty was02 percent of reading then measure-
ment uncertainty improves through use
of Coriolis to 01 percent of reading
giving a 01100 x $14400000 im-
provement in control of the ingredient
annually or $14400 A two-wire Coriolis
mass flowmeter with 01 percent mass
flow accuracy would be paid for in ap-
proximately 6-8 months In practice the
improvement in measurement uncer-
tainty would be greater as the operator
would gain temperature and density in-formation from the Coriolis and the mea-
surement would be devoid of any fluid
property dependence Viscosity change
for example can have a major impact on
turbine meter performance Mechanical
wear and tear that turbine meters even-
tually experience which causes them to
under-register flow is precluded by mod-
ern devices like Coriolis
Furthermore if the process ingredient
was being blended with another then ad-
ditional process improvements could berealized through in-line blending control
using Coriolis technology for final density
as the control point It is possible to have
dual 4-20 mA outputs from two-wire
loop-powered meters but as the main
4-20 mA output representing the prima-
ry variable is also HART then an external
HART Loop Converter or HART IO card in
the control system can provide second-
ary tertiary and quaternary variables as
4-20 mA signals A Coriolis meter is trulya multi-variable device Certain two-wire
devices are also available with Profibus
or Foundation Fieldbus communication
Cutting Wiring CostsIn 2003 WIBEXERA (International
Instrument Usersrsquo Associations) Report
T 2732 X 03 was published and it pro- vided an average survey of prices quoted
in projects at that time for the provision
of power supplies for four-wire instru-
ments The price ranged from euro1200
to euro1800 per instrument depending
upon design and plant characteristics
for an average cost of euro1500 (about
$2000) It would be reasonable to
assume an inflationary factor of 2 per-
cent per annum giving an approximate
current-day figure of $2500
From another source within thechemical industry an estimation of
$40foot to $50foot was given for in-
stallation of four-wire cabling For a
linear 50-foot cable run with for ex-
ample a 10-foot vertical at each end
this equates to $3150 Actual costs
and budget estimates have been given
as high as $10000
The Extent of the Opportunity The modern post-war flow measure-
ment technologies have different powerrequirements and consequently they
are not all available for the
same size range in two-wire
loop-power form For example
two-wire Coriolis flowmeters
are limited to 2rdquo diameter
electromagnetic and inline
low-pressure gas ultrasonics
are limited to 8rdquo and vortex
and inline liquid ultrasonic are
limited to 12rdquo
Nevertheless for thechemical industry in particu-
lar perhaps two-thirds of the
process pipes in a plant will be no larger
than 2rdquo and even when the host process
pipe is larger a correctly sized flowmeter
can still be less than 2rdquo There is consid-
erable scope for two-wire loop-power to
deliver value for flow measurement ap-
plications with total safety
The virtues of Coriolis technology
have been covered but what about
other two-wire technologies An elec-tromagnetic flowmeter in two-wire form
YSTEMS DESIGN | Flow Measurement
In todayrsquos volatile global mar-
ketplace return on investment
calculations for plant upgrade or
new plant construction projects
may go through several itera-
tions before the trigger is finally
pulled or indeed not pulled
ldquo
rdquo
COURTESYENDRESS+HAUSER
Figure 2 Two-wire Coriolis flowme- ters became available in 2011
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2245
can be used on water wastewater or
a light water-based slurry provided the
fluid has around a 20 microSeimenscenti-
metre (microScm) electrical conductivity
A magnetic flowmeter is full bore un-
less flowrates dictate a reduced meter
size in the interests of performance and
so there are no intrusions into the flow
stream and no pressure loss An accu-
racy of 05 percent of reading is normal
from a two-wire magnetic meter and a
modest five diameters (5D) of straight in-let run is needed to avoid error from up-
stream flow disturbances When the fluid
exhibits insufficient conductivity then
the same performance and installation
requirements can be met by an inline ul-
trasonic flowmeter provided the liquid is
essentially clean and bubble-free
For gas or steam applications a vor-
tex meter is the normal choice Using a
built-in temperature sensor a two-wire
loop-powered vortex meter can calculate
mass flow of saturated steam using in-ternal steam tables An external pressure
input allows mass flow of steam to be ac-
curately calculated even when saturated
steam becomes superheated as can oc-
cur downstream of a pressure regulating
valve With mass flow known the vortex
meter can calculate energy and heat flow
A new and exciting development is
the ability of the vortex meter to indicate
wet steam and calculate dryness frac-
tion or steam quality For safety and ef-
ficiency saturated steam should be dry
and free from condensate that is to say
it should possess a high steam quality
factor However the dry or wet state of
saturated steam can sit on a knife-edge
and shift to the opposing state due to
the slightest change in process condi-
tions Rapid and reliable indication of
this change of state is now available
Perhaps the most astonishingachievement in the power management
of two-wire loop-power flowmeters is
that of the ultrasonic biogas meter It is
now possible not only to measure the
flow of wet dirty variable composition
and low-pressure anaerobic digester
gas landfill gas and coal bed methane
gas with a two-wire loop-powered ultra-
sonic flowmeter but also the same de-
vice uses an inbuilt temperature sensor
in combination with measured sound
velocity to calculate methane contentcalorific value and energy flow
Technology to Take UsForwardModern flow technologies provide instru-
ment engineers with vital self-monitoring
information The format of such infor-
mation is easier to understand and act
upon when presented in accordance
with harmonized international guidelines
for online plant asset management eg
NAMUR Standard 107
Continuous plain-text self-diagnostic
and process-related information with
suggested remedies (Figure 3) make it
possible for instrument engineers andoperators to take action at the appro-
priate time mdash immediately or during
the next scheduled shutdown mdash saving
time and money by knowing the exact
health of their measuring point and the
probable actions required to rectify any
abnormal conditions Device verifica-
tion offering third-party validated trace-
ability can be performed on demand ei-
ther locally or remotely from the control
room without the expense of a man in
the field Calibration is then avoided ordeferred without process interruption
Where a process plant has a large
installed base of older mechanical tech-
nologies the decision to embark upon a
program of replacement for plant mod-
ernization cannot of course be taken
easily There are the stocks of spare
parts to consider along with the plant
instrument technicians who are trained
on and at ease with the old devices
However a process plant that retains
the older technology going forward willbe at risk and may find it increasingly
difficult or even impossible to maintain
a cost position that competes effective-
ly in the global market FC
wwwusendresscom
wwwflowcontrolnetworkcom January 2015 | 19
Steve Milford
is a Flow Product
Business Manager
for Endress+Hauser
Inc in Greenwood
Ind He has been
involved in flow
measurement since
1983 and has been
actively involved with standards devel-
opment for flow technology within the
International Standards Organization
(ISO) and the British Standards
Institute Mr Milford can be reached
at stevemilfordusendresscom
Steve Milford
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Coriolis Flowmeter | Magnetic Flowmeter | Two-Wire | Ultrasonic Flowmeter | Vortex Flowmeter
Figure 3 A modern instrumentrsquos display module can provide continuous plain- text self-diagnostic and process-related information
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2345
The bottom line is the volume of gas under one set of
pressure and temperature conditions is not the same as it
would be for the gas under different conditions Why is thisimportant Without compensation for compressibility read-
ings taken by gas flowmeters can result in measurementsmdash
and costs to the buyermdashsignificantly lower or higher than they
should be
The flow of gas in a system can be accounted for and
reported in a number of ways such as by volume by mass
flowrate and by energy Inline turbine meters can offer both
reliability and accuracy in measuring gas flow when matched
with a monitor capable of calculating and displaying results
that have been adjusted for the nature of the gas and impor-
tantly the pressure and temperature
Measuring Flow with an Inline TurbineFlowmeter
With an inline turbine meter gas flows into the meter through
a length of piping that helps to pre-condition the flow by
reducing undesirable swirls and asymmetry Where consid-
ered necessary a flow straightener may even be installed in
line to create a uniform flow profile to the extent possible
As can be seen in Figure 1 a rotor support within the tur-
bine housing further conditions the flow and directs it through
the blades of the rotor High-precision ball bearings allow the
rotor to freely rotate on the shaft
The rotorrsquos rotational speed is directly proportional to the velocity of the fluid passing through the meter The rotor itself
incorporates magnets (or magnetic blades depending on thedesign) while the housing is non-magnetic
A proximity sensor (also known as a pickup coil) is located
in line with the rotor and detects the electrical pulses gener-
ated by the ferrous rotor spinning through the magnetic field
Each pulse represents a discrete volume of gas The out-
put frequency provides the indication of the gas flow rate and
the accumulated pulses over a specified time represent the
total volume of fluid for that measurement period
Need for Calibration The flowrate of the gas through the meter cannot be deter-
mined accurately unless the meter is calibrated The fac-tory calibration determines the meterrsquos constant known
as a K-factor which is then inputted into the gas monitor
PPLICATION NOTES | Flow Measurement
20 | January 2015
Flow Control Magazine
COMPENSATING for
Compressibility inMeasuring Gas Flow Why K-factor adjustment is essential foraccurate inline turbine flow measurement
Unlike crude oil and other liquid fossilfuels natural gas poses a challenge
in monitoring the quantity of gas flowing
through pipelines While liquids do not com-
press gases do and the mass flowrate of
gas being transmitted through gathering
lines depends on both the pressure and
temperature
By Kevin Clark
Figure 1 Internal components of a liquid turbine flowmeter
C O U R T E S Y
T U R B I N E S
I N C
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2445
Wondering Whether the
Pump Guy Seminar
Is for YouCheck out the ldquoPump Guy Insightsrdquo
video series flwctrlcompginsights
PUMP GUY INSIGHT 1NPSHa vs NPSHrmdashWhy all pumps need gauges
PUMP GUY INSIGHT 3How to Operate Your Pump at Best Efficiency
PUMP GUY INSIGHT 5Head vs Flow
PUMP GUY INSIGHT 2 Your Pumps Are Constantly Moving On Their Curves
PUMP GUY INSIGHT 4 The Role of the Pump Reliability Chain
PUMP GUY INSIGHT 6How to Read a Pump Curve
PARTNER SPONSORSFor more information and to register
for upcoming Pump Guy Seminars
visit FlowControlNetworkcomPumpGuy
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2545
PPLICATION NOTES | Flow Measurement
22 | January 2015
Flow Control Magazine
Gas flowmeters measure the actual volume of gas passing
through the meter per minute irrespective of pressure and
temperature1
The volumetric flowrate of a gas is often corrected to
ldquostandardizedrdquo conditions of pressure and temperature While
ldquostandardrdquo conditions can vary depending on the definition
in the US this typically means a pressure of 1473 PSIA(pounds per square inch absolute) and a temperature of 60 F
The flowrate measurement is reported in standard cubic feet
per minute (SCFM)
Compensating for changes in pressure and temperature is
critical Consider a meter system setup for flowing conditions
of 60 PSIG (pounds per square inch gauge) and 60 F and the
line pressure decreases to 50 PSIG while the temperature
remains constant The difference in SCFM between the two
is more than 15 percent which would cost the buyer more
for the gas than it should As Table 1 demonstrates even a
small variation in pressure will result in a surprisingly high er-
ror percentage
Automation of the K-Factor The K-factor is established by an initial factory calibration In
the case of a non-compensated flow monitor any variations
in pressure and temperature will result in manual adjust-
ments needed to the K-factor In order to maintain accurate
flow measurement users must monitor pressure and temper-
ature and make corresponding adjustments to the K-factor To eliminate these manual adjustments some suppliers offer
a flow monitor that automatically adjusts for any changes in
pressure and temperature
These monitors provide accurate flow measurement regard-
less of changing environmental conditions in some cases sup-
porting applications with pressures as high as 15000 PSIG and
temperatures between -350 F to 350 F with a standard accura-
cy of +-1 percent over a flow range of 05 ACFM to 650 ACFM
Final NotesDuring the operation of a flowmeter system the ability to obtain
a readout mdash and to adjust for line pressure and temperaturechanges mdash is sometimes compromised by a lack of electric
power This issue is especially true along gas pipelines in remote
areas To overcome this limitation some manufacturers have
designed low-powered flow monitors which can operate for up
to on year on a single lithium D-cell battery
It is important for users to recognize the effects of the
compressibility of gas As such the quantity of a gas flow-
ing through a gas flowmeter depends on the pressure and
temperature In order to ensure accuracy any flowmetering
system must employ a means to correct for these effects
Otherwise the readout is certain to be in error and could be
unnecessarily costing money This is particularly crucial onwellhead production and in billing scenarios FC
wwwturbinesincorporatedcom
Notations1 The measurement factor in the US is known as the
ACFM actual cubic feet per minute (Metric units are typically
ACMH actual cubic meters per hour)
Table 1 Error induced by line pressure changes
Constant Temperature with Varying Pressure
Pressure Temperature PulsesSCF Error
50 60 2556027821 1546
51 60 2517123288 1370
52 60 2479385307 1199
53 60 2442762186 1034
54 60 240720524 873
55 60 237266858 717
56 60 2339108911 566
57 60 2306485356 418
58 60 2274759285 275
59 60 2243894166 136
60 60 2213855422 000
61 60 2184610304 132
62 60 2156127771 261
63 60 2128378378 386
64 60 210133418 508
65 60 2074968632 627
66 60 2049256506 743
67 60 2024173807 857
68 60 1999697703 967
69 60 1975806452 1075
70 60 1952479339 1181 Flow Measurement | K-Factor | Measurement
Accuracy | Turbine Flowmeter
Find related content flowcontrolnetworkcomhellipSearch on
FLOWSTREAM
Kevin Clark is senior develop-
ment engineer for Turbines Research
amp Development LLC Turbine RampD is a
subsidiary and the research and techni-
cal support arm of Turbines Inc which
serves a range of industries and applica-
tions from oil amp gas to cryogenic liquids
to custody transferKevin Clark
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2645
Pumps Bearings amp Seals TECHNOLOGY REPORT
FEATURES
SYSTEMS DESIGN
The ComplicatedCase of
Compressors
withSide-Streams
24 28 32BEST PRACTICES
How PumpingSystems
AffectSealing
Performance
TECH OUTLOOK
BearingSuppliers
Drive Gains InDeveloping
Markets
wwwflowcontrolnetworkcom January 2015 | 23
S P E C I AL S E C T I O N
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2745
The design and operation of compressors with side-
streams has always been difficult because flow entering the
compressor needs to be mixed with the core flow already
in the compressor (compressed in section-1) in a manner
that does not degrade the aerodynamic performance of sur-
rounding sections Minimizing losses and ensuring proper
mixing of the side-stream flow and core-flow are required to
ensure effective performance of a compressor of this sort
Key considerations for an application involving compres-
sors with side-stream flow include
The plant process typically dictates the side-stream
flange pressure
The impellers upstream of the side-stream should
achieve the necessary pressure for the core-flow
The side-stream flow is typically at a temperature dif-
ferent from compressor core-flow temperature
Process plants need some degree of operational flex-
ibility ie the ability to support variations in core-flow condi-
tions and side-stream conditions
Modern process plants are usually specifying more than
one operating conditions (sometimes two or more manda-
tory conditions) which can present challenges to compres-
sors with side-streams Adding to these issues modern
compressors should operate with much higher impeller tip
The COMPLICATED CASE ofCompressors with Side-StreamsConsidering key system design requirements
to ensure operational efficiency By Amin Almasi
4 January 2015
Flow Control Magazine
|
y
g
Some compressors in certain applications
have one or more incoming side-streams
(or side-loads) that introduce side-stream
flow to mix with the core flow In other words
a radial side-stream inlet is utilized in multi-
impeller centrifugal compressors to introduce
additional gas into the mid-stage of a com-
pressor This design enables optimization in
some process plants However the flow dis-
tribution after the junction of the side-stream
and the main return channel of the upstream
section can significantly affect the perfor-mance of the next section of compressor
In most cases the pressure levels at these
side-streams should be accurately predicted
to meet the theoretical performance
Compressor station at a natural gas processing plant
R U D M E R Z W E R V E R I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2845
speeds and inlet Mach numbers compared to previous
generations of compressor technology
Likewise side-streams are now com-
monly used with medium-sized and
large-sized compressors (eg 1ndash60
MW) The costs associated with cor-
rections on side-stream compres-
sor applicationsmdashany repair
inefficient operation and power
lossesmdashwould be very high Fur-
ther compressors with side-streams
are usually sensitive and difficult
machines to operate In particular
performance curves (performance
pressures efficiency etc) are sen-
sitive to suction inlet conditionsside-stream inlet conditions vol-
ume flow ratio (side-stream vol-
ume to core-flow volume) and side-stream losses
Compressors with side-stream often perform far below
expectations The main reason is that side-stream compres-
sors are different than conventional compressors (without
a side-stream) in design and operation For a compressor
with side-streams tighter tolerances in operating conditions
must be identified and applied Uncontrolled variations of
suction pressure or side-stream pressure are major prob-
lems Another major issue is the variations of the flow ratio
(side-stream flow to core-flow)
Compressor Side-Stream amp Mixing SectionIn many centrifugal compressors the portion of the side-
stream system from the flange connection to the mixing
section is similar to a compressor inlet A great challenge
is ensuring the mixing section provides circumferentially
uniform merged-flow with minimum losses This can be
achieved via effective design of the inlet configuration and
mixing section of the side-stream compressor such that
the impeller can be maintained over the whole operating
range of the compressor In many cases while there are
mixing sections provided for the machine the flows do not
completely mix before entering the impeller of the section-2
(the impeller after the mixing section) Non-uniformity at
inlet flow to the impeller is a key concern for compressor
performance
Another consideration is a compact design of the side-
stream mixing section Specifically a mixing section with
less axial length is always preferred This axial length can af-
fect the compressor rotor dynam-
ics the rotor length and over-
all compressor performance
(design cost operation and
reliability)
The side-stream exit pressure
(side-stream pressure at inlet
of the mixing section) is mainly
a function of the side-stream
flow velocity and the pres-
sure in the previous section of
the compressor Conversely the side-
stream flange pressure can depend on
side-stream flow velocity and section-1
exit conditions Therefore the side-stream
inlet flange volume flow is a function of theflange pressure compressibility (at that
pressure and temperature) and mass flow
Some engineers assume that the side-stream flange pres-
sure is equal to the inlet pressure of the first impeller of the
section-2 This is not true The mixed total pressure can be
estimated on a mass-averaged basis using side-stream total
pressure and return channel exit (section-1) total pressure
In some designs because of the lower static pressure at
the side-stream exit the total pressure at the return channel
exit is lower even though the velocity upstream is roughly
matched for both streams The pressure usually increased
at the returned channel but it can be reduced again at the
side-stream exit While simple in nature this can have an
impact on the prediction of pressure at the side-stream exit
and overall mixing section performance Based on basic flow
principles it was usually assumed that the static pressure
was equal between both flow streams at the mixing location
While this assumption might be used in rough calculations
the accurate simulations have shown this assumption is not
true In fact there are some points (for instance the shroud
wall at the exit of the return channel and the hub wall at
the exit of the side-stream) where this assumption is true
However this is not valid for all locations There are pressure
changes that occur from a side-stream flange to the inlet
of the next section (section-2) which depend on different
factors The first factor is the frictional losses due to side-
stream geometry from side-stream flange to plenum mix-
ing section etc The other factors are pressure changes due
to local curvature and geometry details of mixing section
Another consideration is the operation of a compressor
with side-stream at part-load The performance of the side-
wwwflowcontrolnetworkcom January 2015 25
Figure 1 An example of a centrifugalcompressor with side-stream
COURTESY SIEMENS
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 29456 January 2015
Flow Control Magazine
|
y
g
stream path the mixing section and
the downstream impellers when ma-
chine is operated at part-load or even
off-design operating flows will result
in additional compressor performance
problems In such a case both veloc-
ity profiles and pressure variations in
various parts (side-stream path mixing
section etc) will be different resulting
in complicated flow patterns and com-
plex aerodynamics behaviors
Side-Stream CompressorSectional Performance
Typically vendor-supplied compressor
performance curves reflect flange-to-flange performance because that is
what the plant engineers need to
evaluate the proper operation of their
system (for example from suction to
side-stream and from side-stream to
discharge) In many cases compres-
sor vendors also provide the over-
all compressor performance curves
and performance curves for section-1
(from suction to side-stream) and sec-
tion-2 (from side-stream to discharge)
Flange-to-flange data if not interpret-
ed properly can lead to false conclu-
sions about the relative performance
of individual sections of a compression
system For example if side-stream
losses from the flange to mixing sec-
tion are attributed to the downstream
section (section-2) it will cause the
downstream section (section-2) to
appear low in performance while the
upstream section (section-1) will show
high performance levels
An important behavior to con-
sider is when the actual side-stream
pressure is different than the rated
side-stream pressure When the side-
stream pressure is slightly higher than
the outlet pressure of the section-1
it (section-1) shows a relatively higher
performance compared to the real sec-
tion-1 performance In some cases
the performance of section-1 could be
considerably higher than section-2 In
other words when performance is de-
termined flange to flange the higher
flange pressure is seen as extra ldquopseu-
dordquo work done by the section (since this
is an inconsistent thermodynamic vol-
ume) resulting in a relatively high sec-
tional efficiency (section-1 shows a rel-
atively high efficiency) This is the case
for many compressors with side-stream
because the whole system is designed
(or specifically the side-stream location
is selected) in a way aimed at main-
taining the real side-stream pressure(side-stream inlet) above the section-1
outlet pressure because if the real side-
stream pressure becomes lower than
the section-1 outlet pressure the flow
may (theoretically) reverse
This is particularly important when
the side-stream mass flow is much
lower than the mass flow of core-flow
The above-mentioned reasons explain
why in many simulations calcula-
tions and performance reports related
to compressors with side-stream the
section-1 shows a relatively good ef-
ficiency and section-2 appears low in
efficiency
When the side-stream pressure is
slightly lower than the outlet pressure
of the section-1 the section-1 might
show a relatively lower performance
compared to section-2 This could oc-
cur in some recycle services where the
side-stream is actually a recycle flow
with a mass flow around two to five
times the core-flow The side-stream
(recycle) flow is returned from down-
stream of the compressor to be slightly
compressed and recycled to the down-
stream Such a recycled side-stream
compressor can present unique chal-
lenges for design and operation This
kind of machine usually needs very
special operating procedures and very
fine adjustments regarding operating
pressures and flows
Side-Stream Compressor
Performance amp Operation An important consideration is the sen-
sitivity of compressor overall perfor-
mance curve and sectional perfor-
mance curves to the flow ratio (ratio
of side-stream flow to core-flow) and
to the inlet conditions Variations in
the flow and pressure of the main
suction and side-stream inlet should
be controlled within tight tolerances
For compressors with side-stream the ASME PTC-10 code stipulates limits on
flow ratio (side-stream volume to core-
flow volume) The acceptable variation
in volume flow ratio in a compressor
with a side-stream is +-5 percent as
per ASME PTC code The requested
side-stream pressure tolerance is not
usually specified in compressor codes
but it should be around +- 2 percent
(or sometimes +- 25 percent)
Variance in flow ratio impacts the
velocity levels where the two streams
merge Significant variation in the ve-
locity profile upstream of the impeller
changes the incidence on the blade
leading edge of the following impel-
ler This change in incidence leads to a
change in sectional performance over-
all compressor performance and train
efficiency
If the flow ratio is varied between 95
percent and 105 percent (tolerances
specified in the ASME PTC-10 code)
the flange pressure changes accord-
ingly resulting in a change in the sec-
tional performance and overall perfor-
mance The sectional efficiency varies
sometimes more than +- 4 percent
This variance reduces as the flow is de-
creased toward surge However as the
flow is increased toward overload the
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3045wwwflowcontrolnetworkcom January 2015 27
variance increases up to higher values
(even in some cases three to five times
compared to variations near the surge
zone) For example in a case study
for a compressor with side-streams a
+- 5 percent variation in flow ratio and
associated changes (pressures losses
etc) the sectional efficiency reduced by
approximately 34 percent at the rated
flow at allowable operating points at
the end of curve (near the overload
ie choke) efficiency reduced by ap-
proximately 55 percent These results
show that the variation in sectional
performance and overall performance
due to flow ratio is highest at operat-ing points near the overload and low-
est at operating points near the surge
For compressors which work most of
the time at high flow (flow higher than
rated flow and discharge pressure low-
er than rated pressure) the effects of
flow ratio deviations (and subsequently
efficiency reduction) would be higher
than compressors working on the left-
hand side of curve (say with sufficient
margins near the surge)
In the compressor codes (such as
API 617) the compressor power varia-
tions should be maintained below 4
percent However in some applica-
tions clients require tighter tolerances
on the consumed power sometimes
below 2 percent (or even below 15
percent) Some studies suggest while
+- 5 percent of volume flow ratio is
suitable for performance test as per
ASME PTC-10 code some plants re-
quire tighter control on the consumed
power and compressor performance
(lower limits on the efficiency) the tol-
erances on the volume flow ratio could
be tighter than ASME PTC code In this
regard +- 4 percent tolerance can be
suggested on the volume flow ratio (ra-
tio of side-stream flow to core-flow) of
compressors with side-streams
Based on operational experiences
acceptable variations in volume flow
ratio and inlet pressures (suction inlet
and side-stream inlet) of a compressor
with side-streams are +- 4 percent
and +- 2 percent respectively
Another important consideration is
the required adjustments for the flow
ratio (side-stream flow to core-flow)
Compressors with side-stream usually
require fixed side-stream flange pres-
sures For a compressor with some variations in operation conditions (even
small changes) it is not usually pos-
sible to achieve optimum operation by
keeping the flow ratio (side-stream to
core-flow) constant The flow ratio has
to be adjusted according to the inlet
flow at which the machine is operating
in order to get the required correspond-
ing side-stream flange pressure
Thermal changes have also been
known to cause some instability in
centrifugal compressors An example is
the thermal-induced change of resid-
ual unbalance For compressors with
side-streams which feature tempera-
ture differences between core-flow and
side-stream flow the thermal behav-
ior of the compressor is usually more
complex and requires more attention
Heavy Gas ChallengeHeavy gases (such as heavy hydrocar-
bon gases eg propane propylene
MTBE (Methyl Tertiary Butyl Ether))
have very low gas sonic velocities that
produce high Mach numbers in the
aerodynamic flow paths For these
services because of high Mach num-
ber high flow coefficient stages have
very narrow flow maps characterized
by limited surge and choke margins
Compressors with side-streams in
these services present great challeng-
es This is to say the side-streams and
associated mixing further complicate
design operation and performance
prediction because the pressure tem-
perature and flow conditions at each
one of these side-streams as well
as at the exit of the machine require
stringent tolerances to optimize the
overall efficiency and performance
As such it is important to accuratelymodel design operate and moni-
tor performance characteristics of any
impellers diffusers return channels
and generally all flow-path components
in a compressor with side-stream FC
Amin Almasi
is a senior rotating
machine consultant
in Australia He is
a chartered profes- sional engineer of
Engineers Australia
(MIEAust CPEng ndash
Mechanical) and
IMechE (CEng MIMechE) holds
bachelorrsquos and masterrsquos degrees
in Mechanical Engineering and is
a registered professional engineer
in Queensland He specializes in
rotating machines including cen-
trifugal screw and reciprocating
compressors gas turbines steamturbines engines pumps subsea
offshore rotating machines LNG
units condition monitoring and reli-
ability Mr Almasi is an active mem-
ber of Engineers Australia IMechE
ASME and SPE He can be reached
at aminalmasiymailcom
Amin Almasi
Compressor | Gas Flow | Performance Curve | Side-Stream Flow
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3145
The pressure in the stuffing box
containing the packing can be estimat-
ed by the following equation
SBP = [Discharge ndash Suction] 3 + Suction
Pressure at the bottom of the stuff-
ing box will be higher than the suction
pressure but considerably lower than
the discharge pressure It should be
noted this calculation will yield a con-
servative estimate of stuffing box pres-
sure that can be further reduced by
pump design
A hole in the stuffing box serves as
a port for injecting clean fluid that cir-
culates around a lantern ring aligned
under the flush port The fluid flushes
solids back into the process to protect
the packing from abrasive wear If the
clean fluid is injected at a pressure ex-
ceeding that at the bottom of the stuff-
ing box some of it will leak back into
the process and some will leak out to
the atmosphere Recommended flush
injection pressure is 15ndash30 PSI (1ndash2
Bar) greater than the pressure at the
bottom of the stuffing box
Fluid injection is also used to lubri-
cate and cool dry-running packing that
is subject to frictional heat and to pre-
vent air from entering the pump which
reduces flow and operating efficiency
Centrifugal pumps utilize three
types of impellersmdashopen semi-open
and closed (Figures 2 3 amp 4) Open
designs prevent fluids with large solids
from clogging the impellers but at theexpense of pump efficiency Backing
plates on semi-open designs serve to
trap the fluid for more efficient opera-
tion Closed impellers are for use with
clean fluids since solids could ac-
cumulate in the eye which would re-
quire tearing down the pump to remove
them
Single-Stage CentrifugalPumpsSingle-stage centrifugal pumps typi-
cally have good bearing support of the
shaft with few run-out or ldquowhiprdquo prob-
lems However in some cases they
are subject to cavitation This occurs
in the eye of the impeller where the
fluid is under vacuum If the pressure
is low enough it will cause the material
to vaporize forming air or water vapor
bubbles As the fluid passes through
How Pumping Systems Design Affects Sealing Performance
By Chris Boss
8 January 2015
Flow Control Magazine
|
Understanding how different types of pump designs impact
sealing is critical to optimizing efficiency safety and lon-
gevity of the sealing system Used for a wide variety of media
including clear fluids solutions and slurries single-stage
centrifugal pumps are one of the most common
types (Figure 1) Fluid drawn into these pumps
enters the eye of an impeller that spins itto the outside of its container
or volute building pressure as
it moves toward discharge
Some of this fluid will work
its way behind the impeller
where it must be sealed with
compression packing or a
mechanical seal
Figure 1
Figure 2 Figure 3 Figure 4
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3245
the pump under increasing pressure
these bubbles implode sending shock
and vibration through the impeller
adversely affecting the seal This phe-
nomenon can be mitigated by running
the pump at slower speed and higher
pressure at the suction end to prevent
air from entering the fluid
Double-Ended Split-CasePumpsOperating on the same centrifugal prin-
ciple but slightly different geometry are
double-ended split-case pumps (Figure
5) Fluid enters both ends of the pump
and is directed into the eye of an impel-ler which spins it out of the volute to
discharge Packing is installed on both
the shaft and bearing ends so the stuff-
ing box is exposed only to suction pres-
sure which is usually quite low
Axial Flow Pumps Axial flow pumps operate like hydro
turbines in reverse whereby a propeller
(or axial impeller) pushes the fluid to
discharge (Figure 6)
Since the stuffing box is located
downstream of the propeller at the dis-
charge end of the pump the packing is
exposed to the full discharge pressure
Vertical PumpsVertical turbine pumps are typically
flange-mounted on a floor extending
downward into a water-filled sump
hole (Figure 7) Available as single- or
multi-stage pumps they feature an
impeller or series of impellers rotated
simultaneously by a single shaft The
impellers increase the pressure of the
upward flow subjecting the stuffing box
to full discharge pressure
Vertical pumps can be quite long so
inadequate bearing support can cause
the shaft to run out This can induce
undesirable lateral motion on the pack-
ing Worse the packing may be forced
to serve both as a bearing and a seal To
withstand these conditions the packing
should be resilient elastic and resistant
to deformation These properties rule
out packing such as graphite foil in favor
of fiber-based materials
Multi-Stage PumpsMulti-stage pumps are used for high-
pressure applications such as feeding
the boilers in steam-powered generating
plants Stuffing box pressure can vary
with pump design and number of stag-
es Designed for clean fluids and high
operating speeds these pumps typically
have high- and low-pressure ends with ahydraulic pressure equalization line run-
ning between the stuffing boxes
Like vertical pumps multi-stage
pumps feature a series of impellers to
build fluid discharge pressure In the
case of the six-stage pump pictured in
Figure 8 fluid enters at the drive end
where a stuffing box is exposed to suc-
tion pressure Channeled from one
impeller to the next through the pump
casting the fluid can reach extremely
high pressures at discharge
A second stuffing box located at the
bearing end is exposed to an intermedi-
ate pressure from the third impeller This
pressure is greater than the suction pres-
sure but much less than the discharge
pressure which can reach 2000 PSI
Fortunately the stuffing boxes in
these pumps are not exposed to dis-
charge pressures and typically see be-
low 500 PSI which is within the range
of some packing materials
wwwflowcontrolnetworkcom January 2015 29
Figure 5
Figure 6
Figure 7
Figure 8
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 33450 January 2015
Flow Control Magazine
| Gear PumpsPositive-displacement or gear pumps
operate on a different principle than
centrifugal pumps In external gear
pumps the fluid flows around the out-
side of the gears the intermeshing
of which forces it through the pump
to discharge (Figure 9) This design
makes these pumps particularly suit-
able for use with highly viscous fluids
such as resins emulsions syrups and
adhesives As such they are used for
transfer or metering applications
It should be noted gear pumps will
continue to displace fluid as long as
their shafts are turning which can pose
a problem if a clog occurs at the dis-
charge The resulting buildup of pres-
sure can blow out seals and damage
the pump Therefore most gear pumps
have pressure relief valves to divert
fluid back to the suction side for re-
circulation through the pump Internal
gear pumps operate slightly differently
but also have pressure relief valves to
prevent damage from excessive pres-
sure (Figure 10) In both external and
internal gear pumps the maximum
stuffing box pressure is determined by
these valves
Other rotating equipment includes
mixersagitators which are similar to
pumps in terms of the speeds to which
the packing is exposed There are ba-
sically three types of mixersagitators
top- bottom- and side-entry Top-entry
models are subject to the same con-
cerns about shaft run-out ldquowhiprdquo and
lateral forces on the paddles that are
encountered in some vertical pumps
Although some fluid may splash onto
the packing these mixers basically run
dry so the packing must have the abil-
ity to dissipate the resulting frictional
heat
In bottom-entry mixers the packing
is always exposed to fluid and may also
be exposed to solids requiring abra-
sion-resistance If the seal fails the en-
tire contents of the tank will eventually
drain out onto the bearings the floor
and other components under the stuff-
ing box
The packing in side-entry mixers may
be fully or intermittently exposed to flu-
id as well as side loading and vibration
Aside from media temperature
speed and other application variables
the configurations and operating prin-
ciples of rotary-type pumps exert differ-
ent forces on the seals used to keep
them from leaking These forces can
spell the difference between accept-
able seal performance and failure
Understanding these differences has
important implications that should be
taken into account to assure proper
sealing selection for long-term trou-
ble-free performance FC
wwwgarlockcom
Chris Boss is
a senior applica-
tions engineer for
Garlock Sealing
Technologies in
Palmyra NY He
has held various
positions in produc-
tion engineering
product development and applica-
tions engineering for the companyrsquos
compression packing division He
is a BSME graduate of the State
University of New York at Buffalo Mr
Boss can be reached at 800 448-
6688 or chrisbossgarlockcom
Chris Boss
Cavitation | Centrifugal Pump | Pump Packing | Sealing System
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Figure 9
Figure 10
Aside from media temperature speed and
other application variables the configurations
and operating principles of rotary-type
pumps exert different forces on the seals used
to keep them from leaking These forces can
spell the difference between acceptable seal
performance and failure
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3445
NS IDERNDUSTRIAL AUTOMATION + PROCESS CONTROL
WANT
INFORMATION
ON THE
automationindustry
SUBSCRIBE NOW at wwwiainsidercouk
Published by Spitzer and Boyes LLC Write in 15 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3545
Frost says the push from developing
economies is important as the market
is technologically mature and seeing
restricted growth in developed econo-
mies This is particularly true in Europe
and North America where recent finan-
cial insta-
bility has
reduced capital expenditure across end-
user industries
Bill Moore senior vice president of
sales development and channel man-
agement for global bearings manufac-
turer SKF says ldquosmartrdquo products and
the expansion of robust reliability pro-
grams are helping to drive new invest-
ment particularly in developed coun-
tries where the cost to compete is
high Frost says the magnitude of
the existing global installed base will
strengthen the need for replacement
and upgrades adding to market de-
mand as well
Frost says despite the potential
in developing economies the focus
on price as a product differentiator
may lead to intense price pressures
among manufacturers and bring down
the value of the overall market in the
short term The growing trend among
consumers to choose low-cost Chinese
imports will complicate this challenge
As price and quality become stan-
dardized across the globe customers
will base more of their purchasing deci-
sions on value-added services accord-
ing to Frost This will push manufactur-
ers to create more maintenance-free
solutions such as lubrication-free
bearings that offer end-users savings
on service and replacement costs and
reduce downtimeldquoOffering a complete line of prod-
ucts with comprehensive services will
be another feather in the cap of ven-
dors looking to widen their consumer
baserdquo notes Frost Industrial Automa-
tion and Process Control Research
Analyst Guru Mahesh
Moore says the trend of outsourcing
manufacturing to regions where labor
and production costs are favorable is
becoming less of a factor
ldquoThe days when cheap labor made
a significant difference in where a prod-
uct is manufactured mdash particularly high
value-added products or high weight
and bulk products mdash are coming to
an end as the cost of transportation
storage and inventory balance out the
benefits of production costs where la-
bor is a smaller percentage of the cost
of manufacturingrdquo Moore says ldquoLocal
manufacturing development will indeed
come to developing countries as their
ability to create markets that generate
economies of scale that support local
production is a clear trend and one that
all manufacturers will pay attention tordquo
Moore says that development of
maintenance-free or predictive tech-
nologies and products will be a sig-
nificant advantage to everyone in the
Bearing amp Coupling Manufacturers Focus
onDEVELOPING Economies
amp EFFICIENCY InnovationBy Amy W Richardson
2 January 2015
Flow Control Magazine
|
gy
Anew study from Frost amp Sullivan (wwwfrostcom) fore-
casts steady growth for the overall bearings and couplings
market based on rapid industrial development in high-growth
regions Specifically Frost predicts development in Mexico
Indonesia Nigeria Turkey Brazil Russia India and Chinawill help boost the bearings amp couplings market from $2206
billion in 2013 to an estimated $2676 billion in 2018
The development of maintenance-freeor predictive technologies will helpboost growth in the bearings market For example SKF is developing products that will automatically notifyusers when a bearing or mechanicalrotating component is approachingthe end of its useful life Pictured hereis an SKF Microlog analyzer a por- table condition monitoring tool
COURTESY SKF
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
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optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
For daily product notes visit the lsquoFeatured Productsrsquo section flowcontrolnetworkcom
ON THE WEB
1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3845
FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
and benefits as well as grids of
instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
services provided for the
mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
Brought to you by Beamex
Your Source For Fluid Handling Videos
Go towwwflowcontrolnetworkcomfreeinfo
Select appropriate issue ofFlow Control Magazine
Select advertisements thatinterest you
Enter your email amp clickldquoSubmit Requestrdquo
1
2
3
4
PRODUCT
INFORMATION
ONLINE
Follow these 4 steps to receive freeproduct information from suppliers
FREE
FEATURED VIDEO How to Calibrate aPressure Measurement Loop
For more information about FlowTube
sponsor packs email FlowControlGrandViewMediacom
7232019 Flow Control January 2015
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THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
Name ________________________________________________________________
Title _________________________________________________________________
Company _____________________________________________________________
AddressCityStateZip __________________________________________________
______________________________________________________________________
Phone ________________________________________________________________
E-Mail ________________________________________________________________
One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545
![Page 12: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/12.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1245
Intelligent Features to Boost Global WaterDesalination Pumps Market
The Global Water Desalination
Pumps Market is expected to grow
at a CAGR of 77 percent from 2015 to
2019 according to a new report from
TechNavio (wwwtechnaviocom)
The report shows demand for water
treatment has increased significantly in
developing countries where fresh wa-
ter resources can be scarce Providing
clean and potable water to huge popu-
lations has become a priority which is
pushing the demand for water desalina-tion pumps in the market according to
TechNavio
The report emphasizes the emer-
gence of intelligent pump systems as
a major driver of market growth In-
telligent pumps possess the ability to
regulate flow and pressure and these
systems can automatically adjust to
process and pump system changes
ldquoIntelligent pump systems are be-
ing adopted by many manufacturers
because of the high level of fault toler-
ance ability which leads to a significant
reduction in the total cost of owner-
shiprdquo said Faisal Ghaus vice president
of TechNavio in a news release ldquoThe
adoption of these systems will also
help industries comply with current Eu-
ropean Union regulations in relation toreduction in energy consumptionrdquo
The growing demand for clean wa-
ter worldwide will continue to augment
the demand for water desalination sys-
tems which will propel the Global Water
Desalination Pumps Market during the
forecast period
trendlines
wwwflowcontrolnetworkcom January 2015 | 9
Write in 8 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
Intelligent pump sys-tems are being adopt-
ed by many manufac-
turers because of the
high level of fault tol-
erance ability which
leads to a significant
reduction in the total
cost of ownership
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1345
HE OUTLOOK | News amp Notes
10 | January 2015
Flow Control Magazine
Hydraulic Fracturing WaterTreatment amp Reuse Expected to Soar
Wastewater treatment spending for
hydraulic fracturing is expected to
grow almost three-fold from $138 mil-
lion in 2014 to $357 million in 2020 in
the US according to a new report from
Bluefield Research
The US hydraulic fracturing industry
consumes over 1 billion barrels of wa-
ter annually producing 450ndash500 mil-
lion barrels of contaminated water for
disposal with only about 14 percent
treated and reused Bluefield cites watersupplies increasingly at risk tighter regu-
lations emerging in key states and costs
of disposal on the rise as factors con-
tributing to the substantial rise in water
treatment and reuse which is expected
to account for 27 percent of total pro-
duced and flowback water by 2020
Overall the US hydraulic fracturing
industry will spend $638 billion in 2014
on water management Water transport
and disposal costs will account for 66
percent of the total water managementspent this year with treatment compris-
ing roughly 2 percent
Bluefield reports water scarcity in
Western US states has had little im-
pact to date on fracturing water supply
but that is likely to change if droughts
persist Meanwhile state regulators are
beginning to tighten control of produced
water disposal In Pennsylvania where
policymakers in 2010 placed discharge
limits on wastewater from unconven-
tional oil amp gas operations statewide
treatment and reuse rates for the Mar-
cellus jumped to 90 percent in 2014
The increasing cost of transport and
injecting water into wells mdash now ac-
counting for 66 percent of water servicesspending mdash and the improving cost
structures of treatment provide another
driver of reuse Bluefield reports Well
operators that employ treatment and re-
use solutions spend on average $880
per barrel of water used compared to
$1020 per barrel of water trucked and
injected into wells although cost com-
parisons are site specific
ldquoFracking has been the Wild West for
the US water industryrdquo said Reese Tis-
dale president of Bluefield Research ina prepared statement ldquoThere are three
reasons for this first there has been
an explosive build-out of fracking well
installations now surpassing 126000
Second there has been a lack of clear
regulation on water management in key
markets And third there is not a one-
size-fits-all treatment solution for frack-
ing meaning solutions providers have
had to ascend a steep learning curve
to treat the variable wastewaters that a
single well is capable of producingrdquo
Tisdale notes that these inhibitors
while still acute are beginning to take on
a new form This is partially due to signifi-
cant gains in water management experi-
ence realized adoption of more efficientwater management strategies among
well operators and the emergence of
new policy mechanisms from regulators
that are playing catch-up with the fast-
moving hydraulic fracturing industry
trendlines
Treatment2
Disposal
6
Supply10
Storage22
Transport60
US $638Billion
S O U R C E B L U E F I E L D R
E S E A R C H
Write in 23 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
Industry-Leading
Warranties
Temperature Measurement Solutions
bull Probe type industrial RTDsbull Electronic temperature switchtransmitter bull Vapor-actuated remote thermometersbull Digital temperature indicatorsbull Platinum resistance temperature transmitterbull Compact OEM temperature transmitter bull Industrial amp instrument type bimetal thermometersbull Thermowells
1010 West Bagley Road I Berea Ohio 44017 I P 4402430888 I F 4402433472wwwnoshokcom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1445
New Technique Could ReduceEnergy Required for Oil Refinement
UK scientists have developed a
technique they say has the poten-
tial to dramatically reduce the amount
of energy required for the refinement
of crude oil
Professor Martin Schroumlder and Dr
Sihai Yang from The University of Not-
tingham (wwwnottinghamacuk ) have
led a multi-disciplinary team of scien-
tists from Nottingham the Science and
Technology Facilities Councilrsquos (STFC)
ISIS Neutron Facility Oak Ridge Na-tional Laboratory and Diamond Light
Source to discover a porous material
that works like a chemical sponge to
separate a number of important gases
from mixtures generated during crude
oil refinement
According to a news release from
The University of Nottingham the ex-
isting industrial process uses ldquohuge
amounts of energy to separate and pu-
rify these gases so the new technique
has the potential to revolutionize the oil
industry by significantly reducing car-
bon emissions and making the process
more environmentally friendlyrdquo
Commercially UsefulCrude oil is a raw material that is
refined to produce fuel for cars toheat homes and to create polymers
and other useful materials It is made
up of a complex mixture of hydro-
carbons (chemical compounds that
contain only hydrogen and carbon) of
which certain components are espe-
cially commercially useful
One industrial process used to
achieve hydrocarbon separation is
called ldquocryogenic distillationrdquo which is
widely used worldwide and uses vast
amounts of energy to generate the high
pressures and cryogenic temperatures
required to ensure efficient separation
research amp development
wwwflowcontrolnetworkcom January 2015 | 11
PLASTIC CONTROL VALVES FORALL YOUR CORROSIVE APPLICATIONS
PO Box 938 bull Angleton TX 77516Tel (979) 849-8266 bull wwwcollinsinstcom
Collins plastic control valves are
highly responsive control valves
designed for use with corrosive
media andor corrosive atmos-
pheres
Collins valves feature all-plastic
construction with bodies in PVDF
PP PVC and Halar in various body
styles from 12 - 2 with Globe
Angle or Corner configurations and
many trim sizes and materials
Valves may be furnished without
positioner for ON-OFF applications
Call for more information on our
plastic control valves
Write in 9 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1545
of hydrocarbon mixtures into pure components
However researchers say an innovative solution may
have come in the form of a novel chemical sponge This
porous material a metal-organic framework was devel-
oped by the same team at Nottingham just two years ago
Now in research published in Nature Chemistry for the
first time scientists have proven that it can be used toseparate hydrocarbon mixtures without the need for high
process pressures or very low process temperatures
Reusable MaterialsMade from cheap organic materials aluminum nitrate
salt and water the porous material called NOTT-300 is
able to adsorb different gases found in mixtures of hydro-
carbons at different rates making it possible to sepa-
rate them and extract the most useful ones NOTT-300
requires less energy to function than existing methods
as it operates at ambient temperatures and normal pres-
sures researchers say The gases that are adsorbed intoNOTT-300 can be removed without a significant energy
input and therefore the material can be easily reused
The team of scientists from Nottingham used Diamond
the UKrsquos synchrotron science facility as well as STFCrsquos
ISIS Neutron Facility and Oak Ridge National Laboratory
the UKrsquos and USArsquos world-leading neutron facilities re-
spectively to prove that the sponge works under real-life
conditions
Professor Martin Schroumlder Dean of the Faculty of Sci-
ence at Nottingham said in the news release ldquoIt is a very
important to be able to separate different hydrocarbons ef-
fectively and efficiently with low-energy consumption Po-rous solids such as the metal-organic framework system
studied here represent important materials for the future
development of low-energy separation technologies We
are most grateful to our collaborators at ISIS Neutron Fa-
cility Oak Ridge National Laboratory and Diamond Light
Source in bringing this work to fruitionrdquo
Significant Impact on Oil IndustryDr Sihai Yang the winner of Diamond Young Scientist
and BTM Willis Prize is a Senior Research Fellow at
Nottingham He led the project together with Professor
Martin Schroumlder Yang said ldquoWith the help of advancedcentral facilities like Diamond ISIS and ORNL we have
developed a new separation technique which can poten-
tially reduce the energy usage associated with oil petro-
leum and chemical industries which require the separa-
tion of raw hydrocarbons from crude oil
The discovery of the new material NOTT-300 could
have a significant impact on the oil industry by removing
the necessity for some energy-intensive refinement pro-
cesses researchers say
The research was funded by Engineering and Physical
Sciences Research Council (EPSRC) the European Re-
search Council (ERC) The University of Nottingham andLeverhulme Trust
12 | January 2015
Flow Control Magazine
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THE OUTLOOK | News amp Notes
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1645
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 174514 | January 2015 Flow Control Magazine
PPLICATIONS CORNER | Process Instrumentation
This is the final article in a series based on the troubleshoot-
ing of a mysterious unit shutdown due to flowmeter perfor-
mance problems
If yoursquove followed this column for most of 2014 you know
that what should have been a liquid ammonia stream to the
feed plant became problematic due to the occurrence of
bubbles of ammonia gas These bubbles caused an ultrasonic
flowmeter in a unit to indicate zero flow and caused the reactor
to scram (shut down) under warm operating conditions The source of the bubbles was traced back to the pres-
sure drop associated with a control valve located at the
exit of the liquid ammonia tank farm
This issue was resolved by identifying the problem
and fixing it at its source This was a pragmatic ap-
proach at the time (early 1980s) given the operation
of the cooling system in the unit and the limited selec-
tion of applicable flowmeter technologies
By the early 1990s changes were implemented that elim-
inated all process cooling requirementsmdashexcept for the small
jacketed cooler upstream of the liquid ammonia flowmeter In
other words after these changes the entire cooling system
would be operated and maintained to cool a few meters of
one small ammonia pipe Coincidently at about the same
time Coriolis mass flowmeters became more mature and
could reasonably measure the mass flow of liquid streams
with homogeneous low levels of vapor
The convergence of these two events resulted in another
approach to the problem that was not available in the early
1980smdashie install a Coriolis flowmeter that could operate in
the presence of bubbles The purchase and installation of a
Coriolis mass flowmeter was given high priority given its im-pact on unit operation economics and safety (by eliminating
the ldquomidget-makerrdquo (see March 2014 page 14))
Plant requirements and the technology that can meet
plant needs keep changing An excellent solution today can
become outdated in just a few years However there are few
substitutes for understanding fundamentals when addressing
a problem In other words there can be more than one way
to skin a cat FC
wwwspitzerandboyescom
Problem Solved AgainA Coriolis mass flowmeter provides a better solution
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pump performancebull Prevents overpressure in
piping system
bull Wide range of pressuresettings
bull PTFE shaft and diaphragm designs
bull 1 4rdquo - 3rdquo sizes in PVC CPVC PVDFPolypro and PTFE
bull First State approved
thermoplastic valve for
anti-siphon applications
Write in 10 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
David W Spitzer
Ammonia Gas | Coriolis Flowmeter | David W Spitzer | Scram | Troubleshooting
FLOWSTREAM Find related content flowcontrolnetworkcom
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and Boyes
LLC offering engineering seminars strategic marketingconsulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer can be reached at 845 623-
1830 or at wwwspitzerandboyescom
The purchase and installation of a
Coriolis mass flowmeter was given
high priority given its impact on unit
operation economics and safetyldquordquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1845
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7232019 Flow Control January 2015
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Process improvements to increase yield or cut manufactur-
ing costs typically require enhanced process control but the
installed base of measurement instrumentation in a process
plant may simply be unable to facilitate improvements because
of age inadequate performance or unreliability Maintenance
cost and unscheduled process downtime for an aging process
plant can be very damaging to the balance sheet Upgrading
to new more accurate and more reliable instrumentation can
be prohibitively expensive New plant construction must alsomaintain a focus on optimizing costs for the process control
infrastructure The budget approval decision for new plant
construction must weigh such costs against projected market
conditions for the products that the plant is intended to manu-facture In todayrsquos volatile global marketplace return on invest-
ment calculations for plant upgrade or new plant construction
projects may go through several iterations before the trigger is
finally pulled or indeed not pulled
This article describes advances in two-wire instrumenta-
tion specifically in relation to flowmeters that have taken
place in the past few years and the significant cost benefits
that this new technology can realize for plant builders and op-
erators in terms of capital investment and cost of ownership
The Significance of Two-Wire Loop Power
A survey involving 204 participants in the chemical indus-try across Germany Switzerland the UK Canada and the
United States (Manfred Koenig PhD KIM Ludwigshafen
Germany 2006) revealed an 87 percent preference for two-
wire instrumentation versus four-wire in process applications
and 89 percent for utilities This overwhelming preference
may stem from the fact that older process plants were built
with two-wire twisted-pair cable networks connecting all
process units and measuring instruments together in an
overall plant control scheme
However these existing cables are relatively unsophisti-
cated and incapable of supporting anything but low-energy
instrumentation that is insensitive to interference from otherelectrical sources that might be sharing the same cable con-
duit Further the low energy levels supported by these two-
wire loops are more easily rendered safe in terms of explo-
sive risk in hazardous areas containing flammable materials
Many older process plants are also likely to have a significant
installed base of flowmeters employing pre-war (pre-1945)
technology such as positive displacement (PD) turbine vari-
able area (VA or Rotameter) and differential pressure (dP)
Market data firm Flow Research Inc (wwwflowresearch
com) indicates collectively a future compound negative annual
growth rate approaching minus 3 percent to 5 percent for PD
turbine and VA flowmeter types while dP is expected to keeppace with market growth (World Market for Flowmeters 2010)
YSTEMS DESIGN | Flow Measurement
16 | January 2015
Flow Control Magazine
The Two-Wire
ADVANTAGENew wiring options enable modern instrumentsto drive cost savings in existing plant systems
By Steve Milford
Advances in two-wire instrumentation have enabled mod- ern technology to be employed to the advantage of older
plant and process systems
Some chemical manufacturing plants are
competing for survival not only externally
against other global companies but also
internally among the global facilities of theirown company Other industry sectors face
similar challenges
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2045wwwflowcontrolnetworkcom January 2015 | 17
The Need to Replace Older TechnologiesUntil the 21st century two-wire loops were only able
to support these relatively unsophisticated instruments
which convert their measurement by various means into a
4-20mA output or pulse signal to the control system The
more advanced post-war flowmeter technologies such as
Coriolis ultrasonic or electromagnetic flowmeters have
until just eight years ago required a dedicated power sup-
ply for their function in addition to the output loop and
thus a four-wire infrastructure was required as a minimum
Therefore upgrading older two-wire meter devices to moremodern four-wire technology could require significant
expenditure in terms of the installation of separate power
cables and supply modules
There was a major breakthrough in 2006 when a true
two-wire loop-powered inline liquid ultrasonic flowmeter
was introduced (Figure 1) The nature of this breakthrough
was innovation in device power management This was the
missing piece up to that point because to be a true loop-
powered device the meter had to directly provide a full 16
mA span using less than 36 mA of remaining loop current
and less than 1 Watt of electrical energy The flowmeter
operated on a single 4-20 mA HART two-wire loop wasremotely powered by a DC supply was certified Class 1 Divi-
sion 1 and could be deployed as Intrinsically Safe through
the use of an approved safety barrier
A true two-wire loop-powered Coriolis flowmeter followed
in 2011 (Figure 2) employing a new and more advanced
common electronics platform A two-wire loop-powered inline
ultrasonic flowmeter for low-pressure gas was introduced in
2012 and a second two-wire loop-powered Coriolis meter fol-
lowed in 2013 offering improved measurement performance
and an additional high-performance meter tube material
Electromagnetic and vortex flowmeters had already been
available for some years in two-wire loop-powered form butimproved performance resulted as these designs were incor-
COURTESYENDRESS+HAUSER
Figure 1 A two-wire ultrasonic flow- meter released in 2006 operated ona single 4-20 mA two-wire loop
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I I I I LL I
I I I I LL I
copy COPYRIGHT 2015 OMEGA ENGINEERING INC ALL RIGHTS RESERVED
1-888-826-6342
Prices listed are those in effect at the time of publication and are subject to change without noticePlease contact OMEGArsquos sales department for current prices
FPD3000 SeriesStarts at$630
FPD3300 SeriesStarts at
$790
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OSXL-TIM3$999
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Positive Displacement Flow Meterfor Fuels and Oils
bull Aluminum Bodybull FKM Sealsbull Temperatures up to
80ordmC (176ordmF)bull NPT or BSP Threadsbull DIN JIS or ANSI
Connection (Availableon 1 and Larger Sizes)
Positive DisplacementFlow Meter for Solvents
Thermal Imaging CameraFor Inspection andFactory Diagnosis
Note Not for ExportUSA Only
Your One-StopSource for Process
Measurement and Control
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 214518 | January 2015
Flow Control Magazine
porated into their new common electron-
ics platform in 2013 So all the ldquomodernrdquo
flow measurement technologies mdash that
is to say those introduced post-war mdash
have become available as two-wire loop-
powered devices with one exception
namely thermal mass (thermal disper-
sion) meters Unfortunately the power
requirements for this technology exceed
what is currently deemed possible withtwo-wire loop-power management
Payback forTechnology UpgradeConsider a 1rdquo process line
containing a liquid process
ingredient costing $1lb at a
mass flowrate of 150 lbmin-
ute We have $150minute
flowing in the line translating
to $9000hour and $72000
per eight-hour shift That cal-culates further to $360000
per five-day working week and
for a working year of 40 weeks for
example that is $144 million Assume
the existing device is a turbine flowmeter
Now imagine a two-wire loop-
powered Coriolis mass flowmeter is
installed in place of the existing meter
The line would need to be drained and
probably one process flange replaced
allowing the Coriolis to fit mechanically
in place of the turbine However thetwo-wire loop already used for carrying
the existing meterrsquos flow signal to the
control room can be used unaltered
for the complete electrical installation
aspects of the Coriolis flowmeter
The upside of the change is signifi-
cant and clear cut Assuming the exist-
ing meter measurement uncertainty was02 percent of reading then measure-
ment uncertainty improves through use
of Coriolis to 01 percent of reading
giving a 01100 x $14400000 im-
provement in control of the ingredient
annually or $14400 A two-wire Coriolis
mass flowmeter with 01 percent mass
flow accuracy would be paid for in ap-
proximately 6-8 months In practice the
improvement in measurement uncer-
tainty would be greater as the operator
would gain temperature and density in-formation from the Coriolis and the mea-
surement would be devoid of any fluid
property dependence Viscosity change
for example can have a major impact on
turbine meter performance Mechanical
wear and tear that turbine meters even-
tually experience which causes them to
under-register flow is precluded by mod-
ern devices like Coriolis
Furthermore if the process ingredient
was being blended with another then ad-
ditional process improvements could berealized through in-line blending control
using Coriolis technology for final density
as the control point It is possible to have
dual 4-20 mA outputs from two-wire
loop-powered meters but as the main
4-20 mA output representing the prima-
ry variable is also HART then an external
HART Loop Converter or HART IO card in
the control system can provide second-
ary tertiary and quaternary variables as
4-20 mA signals A Coriolis meter is trulya multi-variable device Certain two-wire
devices are also available with Profibus
or Foundation Fieldbus communication
Cutting Wiring CostsIn 2003 WIBEXERA (International
Instrument Usersrsquo Associations) Report
T 2732 X 03 was published and it pro- vided an average survey of prices quoted
in projects at that time for the provision
of power supplies for four-wire instru-
ments The price ranged from euro1200
to euro1800 per instrument depending
upon design and plant characteristics
for an average cost of euro1500 (about
$2000) It would be reasonable to
assume an inflationary factor of 2 per-
cent per annum giving an approximate
current-day figure of $2500
From another source within thechemical industry an estimation of
$40foot to $50foot was given for in-
stallation of four-wire cabling For a
linear 50-foot cable run with for ex-
ample a 10-foot vertical at each end
this equates to $3150 Actual costs
and budget estimates have been given
as high as $10000
The Extent of the Opportunity The modern post-war flow measure-
ment technologies have different powerrequirements and consequently they
are not all available for the
same size range in two-wire
loop-power form For example
two-wire Coriolis flowmeters
are limited to 2rdquo diameter
electromagnetic and inline
low-pressure gas ultrasonics
are limited to 8rdquo and vortex
and inline liquid ultrasonic are
limited to 12rdquo
Nevertheless for thechemical industry in particu-
lar perhaps two-thirds of the
process pipes in a plant will be no larger
than 2rdquo and even when the host process
pipe is larger a correctly sized flowmeter
can still be less than 2rdquo There is consid-
erable scope for two-wire loop-power to
deliver value for flow measurement ap-
plications with total safety
The virtues of Coriolis technology
have been covered but what about
other two-wire technologies An elec-tromagnetic flowmeter in two-wire form
YSTEMS DESIGN | Flow Measurement
In todayrsquos volatile global mar-
ketplace return on investment
calculations for plant upgrade or
new plant construction projects
may go through several itera-
tions before the trigger is finally
pulled or indeed not pulled
ldquo
rdquo
COURTESYENDRESS+HAUSER
Figure 2 Two-wire Coriolis flowme- ters became available in 2011
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2245
can be used on water wastewater or
a light water-based slurry provided the
fluid has around a 20 microSeimenscenti-
metre (microScm) electrical conductivity
A magnetic flowmeter is full bore un-
less flowrates dictate a reduced meter
size in the interests of performance and
so there are no intrusions into the flow
stream and no pressure loss An accu-
racy of 05 percent of reading is normal
from a two-wire magnetic meter and a
modest five diameters (5D) of straight in-let run is needed to avoid error from up-
stream flow disturbances When the fluid
exhibits insufficient conductivity then
the same performance and installation
requirements can be met by an inline ul-
trasonic flowmeter provided the liquid is
essentially clean and bubble-free
For gas or steam applications a vor-
tex meter is the normal choice Using a
built-in temperature sensor a two-wire
loop-powered vortex meter can calculate
mass flow of saturated steam using in-ternal steam tables An external pressure
input allows mass flow of steam to be ac-
curately calculated even when saturated
steam becomes superheated as can oc-
cur downstream of a pressure regulating
valve With mass flow known the vortex
meter can calculate energy and heat flow
A new and exciting development is
the ability of the vortex meter to indicate
wet steam and calculate dryness frac-
tion or steam quality For safety and ef-
ficiency saturated steam should be dry
and free from condensate that is to say
it should possess a high steam quality
factor However the dry or wet state of
saturated steam can sit on a knife-edge
and shift to the opposing state due to
the slightest change in process condi-
tions Rapid and reliable indication of
this change of state is now available
Perhaps the most astonishingachievement in the power management
of two-wire loop-power flowmeters is
that of the ultrasonic biogas meter It is
now possible not only to measure the
flow of wet dirty variable composition
and low-pressure anaerobic digester
gas landfill gas and coal bed methane
gas with a two-wire loop-powered ultra-
sonic flowmeter but also the same de-
vice uses an inbuilt temperature sensor
in combination with measured sound
velocity to calculate methane contentcalorific value and energy flow
Technology to Take UsForwardModern flow technologies provide instru-
ment engineers with vital self-monitoring
information The format of such infor-
mation is easier to understand and act
upon when presented in accordance
with harmonized international guidelines
for online plant asset management eg
NAMUR Standard 107
Continuous plain-text self-diagnostic
and process-related information with
suggested remedies (Figure 3) make it
possible for instrument engineers andoperators to take action at the appro-
priate time mdash immediately or during
the next scheduled shutdown mdash saving
time and money by knowing the exact
health of their measuring point and the
probable actions required to rectify any
abnormal conditions Device verifica-
tion offering third-party validated trace-
ability can be performed on demand ei-
ther locally or remotely from the control
room without the expense of a man in
the field Calibration is then avoided ordeferred without process interruption
Where a process plant has a large
installed base of older mechanical tech-
nologies the decision to embark upon a
program of replacement for plant mod-
ernization cannot of course be taken
easily There are the stocks of spare
parts to consider along with the plant
instrument technicians who are trained
on and at ease with the old devices
However a process plant that retains
the older technology going forward willbe at risk and may find it increasingly
difficult or even impossible to maintain
a cost position that competes effective-
ly in the global market FC
wwwusendresscom
wwwflowcontrolnetworkcom January 2015 | 19
Steve Milford
is a Flow Product
Business Manager
for Endress+Hauser
Inc in Greenwood
Ind He has been
involved in flow
measurement since
1983 and has been
actively involved with standards devel-
opment for flow technology within the
International Standards Organization
(ISO) and the British Standards
Institute Mr Milford can be reached
at stevemilfordusendresscom
Steve Milford
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Coriolis Flowmeter | Magnetic Flowmeter | Two-Wire | Ultrasonic Flowmeter | Vortex Flowmeter
Figure 3 A modern instrumentrsquos display module can provide continuous plain- text self-diagnostic and process-related information
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2345
The bottom line is the volume of gas under one set of
pressure and temperature conditions is not the same as it
would be for the gas under different conditions Why is thisimportant Without compensation for compressibility read-
ings taken by gas flowmeters can result in measurementsmdash
and costs to the buyermdashsignificantly lower or higher than they
should be
The flow of gas in a system can be accounted for and
reported in a number of ways such as by volume by mass
flowrate and by energy Inline turbine meters can offer both
reliability and accuracy in measuring gas flow when matched
with a monitor capable of calculating and displaying results
that have been adjusted for the nature of the gas and impor-
tantly the pressure and temperature
Measuring Flow with an Inline TurbineFlowmeter
With an inline turbine meter gas flows into the meter through
a length of piping that helps to pre-condition the flow by
reducing undesirable swirls and asymmetry Where consid-
ered necessary a flow straightener may even be installed in
line to create a uniform flow profile to the extent possible
As can be seen in Figure 1 a rotor support within the tur-
bine housing further conditions the flow and directs it through
the blades of the rotor High-precision ball bearings allow the
rotor to freely rotate on the shaft
The rotorrsquos rotational speed is directly proportional to the velocity of the fluid passing through the meter The rotor itself
incorporates magnets (or magnetic blades depending on thedesign) while the housing is non-magnetic
A proximity sensor (also known as a pickup coil) is located
in line with the rotor and detects the electrical pulses gener-
ated by the ferrous rotor spinning through the magnetic field
Each pulse represents a discrete volume of gas The out-
put frequency provides the indication of the gas flow rate and
the accumulated pulses over a specified time represent the
total volume of fluid for that measurement period
Need for Calibration The flowrate of the gas through the meter cannot be deter-
mined accurately unless the meter is calibrated The fac-tory calibration determines the meterrsquos constant known
as a K-factor which is then inputted into the gas monitor
PPLICATION NOTES | Flow Measurement
20 | January 2015
Flow Control Magazine
COMPENSATING for
Compressibility inMeasuring Gas Flow Why K-factor adjustment is essential foraccurate inline turbine flow measurement
Unlike crude oil and other liquid fossilfuels natural gas poses a challenge
in monitoring the quantity of gas flowing
through pipelines While liquids do not com-
press gases do and the mass flowrate of
gas being transmitted through gathering
lines depends on both the pressure and
temperature
By Kevin Clark
Figure 1 Internal components of a liquid turbine flowmeter
C O U R T E S Y
T U R B I N E S
I N C
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2445
Wondering Whether the
Pump Guy Seminar
Is for YouCheck out the ldquoPump Guy Insightsrdquo
video series flwctrlcompginsights
PUMP GUY INSIGHT 1NPSHa vs NPSHrmdashWhy all pumps need gauges
PUMP GUY INSIGHT 3How to Operate Your Pump at Best Efficiency
PUMP GUY INSIGHT 5Head vs Flow
PUMP GUY INSIGHT 2 Your Pumps Are Constantly Moving On Their Curves
PUMP GUY INSIGHT 4 The Role of the Pump Reliability Chain
PUMP GUY INSIGHT 6How to Read a Pump Curve
PARTNER SPONSORSFor more information and to register
for upcoming Pump Guy Seminars
visit FlowControlNetworkcomPumpGuy
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2545
PPLICATION NOTES | Flow Measurement
22 | January 2015
Flow Control Magazine
Gas flowmeters measure the actual volume of gas passing
through the meter per minute irrespective of pressure and
temperature1
The volumetric flowrate of a gas is often corrected to
ldquostandardizedrdquo conditions of pressure and temperature While
ldquostandardrdquo conditions can vary depending on the definition
in the US this typically means a pressure of 1473 PSIA(pounds per square inch absolute) and a temperature of 60 F
The flowrate measurement is reported in standard cubic feet
per minute (SCFM)
Compensating for changes in pressure and temperature is
critical Consider a meter system setup for flowing conditions
of 60 PSIG (pounds per square inch gauge) and 60 F and the
line pressure decreases to 50 PSIG while the temperature
remains constant The difference in SCFM between the two
is more than 15 percent which would cost the buyer more
for the gas than it should As Table 1 demonstrates even a
small variation in pressure will result in a surprisingly high er-
ror percentage
Automation of the K-Factor The K-factor is established by an initial factory calibration In
the case of a non-compensated flow monitor any variations
in pressure and temperature will result in manual adjust-
ments needed to the K-factor In order to maintain accurate
flow measurement users must monitor pressure and temper-
ature and make corresponding adjustments to the K-factor To eliminate these manual adjustments some suppliers offer
a flow monitor that automatically adjusts for any changes in
pressure and temperature
These monitors provide accurate flow measurement regard-
less of changing environmental conditions in some cases sup-
porting applications with pressures as high as 15000 PSIG and
temperatures between -350 F to 350 F with a standard accura-
cy of +-1 percent over a flow range of 05 ACFM to 650 ACFM
Final NotesDuring the operation of a flowmeter system the ability to obtain
a readout mdash and to adjust for line pressure and temperaturechanges mdash is sometimes compromised by a lack of electric
power This issue is especially true along gas pipelines in remote
areas To overcome this limitation some manufacturers have
designed low-powered flow monitors which can operate for up
to on year on a single lithium D-cell battery
It is important for users to recognize the effects of the
compressibility of gas As such the quantity of a gas flow-
ing through a gas flowmeter depends on the pressure and
temperature In order to ensure accuracy any flowmetering
system must employ a means to correct for these effects
Otherwise the readout is certain to be in error and could be
unnecessarily costing money This is particularly crucial onwellhead production and in billing scenarios FC
wwwturbinesincorporatedcom
Notations1 The measurement factor in the US is known as the
ACFM actual cubic feet per minute (Metric units are typically
ACMH actual cubic meters per hour)
Table 1 Error induced by line pressure changes
Constant Temperature with Varying Pressure
Pressure Temperature PulsesSCF Error
50 60 2556027821 1546
51 60 2517123288 1370
52 60 2479385307 1199
53 60 2442762186 1034
54 60 240720524 873
55 60 237266858 717
56 60 2339108911 566
57 60 2306485356 418
58 60 2274759285 275
59 60 2243894166 136
60 60 2213855422 000
61 60 2184610304 132
62 60 2156127771 261
63 60 2128378378 386
64 60 210133418 508
65 60 2074968632 627
66 60 2049256506 743
67 60 2024173807 857
68 60 1999697703 967
69 60 1975806452 1075
70 60 1952479339 1181 Flow Measurement | K-Factor | Measurement
Accuracy | Turbine Flowmeter
Find related content flowcontrolnetworkcomhellipSearch on
FLOWSTREAM
Kevin Clark is senior develop-
ment engineer for Turbines Research
amp Development LLC Turbine RampD is a
subsidiary and the research and techni-
cal support arm of Turbines Inc which
serves a range of industries and applica-
tions from oil amp gas to cryogenic liquids
to custody transferKevin Clark
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2645
Pumps Bearings amp Seals TECHNOLOGY REPORT
FEATURES
SYSTEMS DESIGN
The ComplicatedCase of
Compressors
withSide-Streams
24 28 32BEST PRACTICES
How PumpingSystems
AffectSealing
Performance
TECH OUTLOOK
BearingSuppliers
Drive Gains InDeveloping
Markets
wwwflowcontrolnetworkcom January 2015 | 23
S P E C I AL S E C T I O N
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2745
The design and operation of compressors with side-
streams has always been difficult because flow entering the
compressor needs to be mixed with the core flow already
in the compressor (compressed in section-1) in a manner
that does not degrade the aerodynamic performance of sur-
rounding sections Minimizing losses and ensuring proper
mixing of the side-stream flow and core-flow are required to
ensure effective performance of a compressor of this sort
Key considerations for an application involving compres-
sors with side-stream flow include
The plant process typically dictates the side-stream
flange pressure
The impellers upstream of the side-stream should
achieve the necessary pressure for the core-flow
The side-stream flow is typically at a temperature dif-
ferent from compressor core-flow temperature
Process plants need some degree of operational flex-
ibility ie the ability to support variations in core-flow condi-
tions and side-stream conditions
Modern process plants are usually specifying more than
one operating conditions (sometimes two or more manda-
tory conditions) which can present challenges to compres-
sors with side-streams Adding to these issues modern
compressors should operate with much higher impeller tip
The COMPLICATED CASE ofCompressors with Side-StreamsConsidering key system design requirements
to ensure operational efficiency By Amin Almasi
4 January 2015
Flow Control Magazine
|
y
g
Some compressors in certain applications
have one or more incoming side-streams
(or side-loads) that introduce side-stream
flow to mix with the core flow In other words
a radial side-stream inlet is utilized in multi-
impeller centrifugal compressors to introduce
additional gas into the mid-stage of a com-
pressor This design enables optimization in
some process plants However the flow dis-
tribution after the junction of the side-stream
and the main return channel of the upstream
section can significantly affect the perfor-mance of the next section of compressor
In most cases the pressure levels at these
side-streams should be accurately predicted
to meet the theoretical performance
Compressor station at a natural gas processing plant
R U D M E R Z W E R V E R I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2845
speeds and inlet Mach numbers compared to previous
generations of compressor technology
Likewise side-streams are now com-
monly used with medium-sized and
large-sized compressors (eg 1ndash60
MW) The costs associated with cor-
rections on side-stream compres-
sor applicationsmdashany repair
inefficient operation and power
lossesmdashwould be very high Fur-
ther compressors with side-streams
are usually sensitive and difficult
machines to operate In particular
performance curves (performance
pressures efficiency etc) are sen-
sitive to suction inlet conditionsside-stream inlet conditions vol-
ume flow ratio (side-stream vol-
ume to core-flow volume) and side-stream losses
Compressors with side-stream often perform far below
expectations The main reason is that side-stream compres-
sors are different than conventional compressors (without
a side-stream) in design and operation For a compressor
with side-streams tighter tolerances in operating conditions
must be identified and applied Uncontrolled variations of
suction pressure or side-stream pressure are major prob-
lems Another major issue is the variations of the flow ratio
(side-stream flow to core-flow)
Compressor Side-Stream amp Mixing SectionIn many centrifugal compressors the portion of the side-
stream system from the flange connection to the mixing
section is similar to a compressor inlet A great challenge
is ensuring the mixing section provides circumferentially
uniform merged-flow with minimum losses This can be
achieved via effective design of the inlet configuration and
mixing section of the side-stream compressor such that
the impeller can be maintained over the whole operating
range of the compressor In many cases while there are
mixing sections provided for the machine the flows do not
completely mix before entering the impeller of the section-2
(the impeller after the mixing section) Non-uniformity at
inlet flow to the impeller is a key concern for compressor
performance
Another consideration is a compact design of the side-
stream mixing section Specifically a mixing section with
less axial length is always preferred This axial length can af-
fect the compressor rotor dynam-
ics the rotor length and over-
all compressor performance
(design cost operation and
reliability)
The side-stream exit pressure
(side-stream pressure at inlet
of the mixing section) is mainly
a function of the side-stream
flow velocity and the pres-
sure in the previous section of
the compressor Conversely the side-
stream flange pressure can depend on
side-stream flow velocity and section-1
exit conditions Therefore the side-stream
inlet flange volume flow is a function of theflange pressure compressibility (at that
pressure and temperature) and mass flow
Some engineers assume that the side-stream flange pres-
sure is equal to the inlet pressure of the first impeller of the
section-2 This is not true The mixed total pressure can be
estimated on a mass-averaged basis using side-stream total
pressure and return channel exit (section-1) total pressure
In some designs because of the lower static pressure at
the side-stream exit the total pressure at the return channel
exit is lower even though the velocity upstream is roughly
matched for both streams The pressure usually increased
at the returned channel but it can be reduced again at the
side-stream exit While simple in nature this can have an
impact on the prediction of pressure at the side-stream exit
and overall mixing section performance Based on basic flow
principles it was usually assumed that the static pressure
was equal between both flow streams at the mixing location
While this assumption might be used in rough calculations
the accurate simulations have shown this assumption is not
true In fact there are some points (for instance the shroud
wall at the exit of the return channel and the hub wall at
the exit of the side-stream) where this assumption is true
However this is not valid for all locations There are pressure
changes that occur from a side-stream flange to the inlet
of the next section (section-2) which depend on different
factors The first factor is the frictional losses due to side-
stream geometry from side-stream flange to plenum mix-
ing section etc The other factors are pressure changes due
to local curvature and geometry details of mixing section
Another consideration is the operation of a compressor
with side-stream at part-load The performance of the side-
wwwflowcontrolnetworkcom January 2015 25
Figure 1 An example of a centrifugalcompressor with side-stream
COURTESY SIEMENS
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 29456 January 2015
Flow Control Magazine
|
y
g
stream path the mixing section and
the downstream impellers when ma-
chine is operated at part-load or even
off-design operating flows will result
in additional compressor performance
problems In such a case both veloc-
ity profiles and pressure variations in
various parts (side-stream path mixing
section etc) will be different resulting
in complicated flow patterns and com-
plex aerodynamics behaviors
Side-Stream CompressorSectional Performance
Typically vendor-supplied compressor
performance curves reflect flange-to-flange performance because that is
what the plant engineers need to
evaluate the proper operation of their
system (for example from suction to
side-stream and from side-stream to
discharge) In many cases compres-
sor vendors also provide the over-
all compressor performance curves
and performance curves for section-1
(from suction to side-stream) and sec-
tion-2 (from side-stream to discharge)
Flange-to-flange data if not interpret-
ed properly can lead to false conclu-
sions about the relative performance
of individual sections of a compression
system For example if side-stream
losses from the flange to mixing sec-
tion are attributed to the downstream
section (section-2) it will cause the
downstream section (section-2) to
appear low in performance while the
upstream section (section-1) will show
high performance levels
An important behavior to con-
sider is when the actual side-stream
pressure is different than the rated
side-stream pressure When the side-
stream pressure is slightly higher than
the outlet pressure of the section-1
it (section-1) shows a relatively higher
performance compared to the real sec-
tion-1 performance In some cases
the performance of section-1 could be
considerably higher than section-2 In
other words when performance is de-
termined flange to flange the higher
flange pressure is seen as extra ldquopseu-
dordquo work done by the section (since this
is an inconsistent thermodynamic vol-
ume) resulting in a relatively high sec-
tional efficiency (section-1 shows a rel-
atively high efficiency) This is the case
for many compressors with side-stream
because the whole system is designed
(or specifically the side-stream location
is selected) in a way aimed at main-
taining the real side-stream pressure(side-stream inlet) above the section-1
outlet pressure because if the real side-
stream pressure becomes lower than
the section-1 outlet pressure the flow
may (theoretically) reverse
This is particularly important when
the side-stream mass flow is much
lower than the mass flow of core-flow
The above-mentioned reasons explain
why in many simulations calcula-
tions and performance reports related
to compressors with side-stream the
section-1 shows a relatively good ef-
ficiency and section-2 appears low in
efficiency
When the side-stream pressure is
slightly lower than the outlet pressure
of the section-1 the section-1 might
show a relatively lower performance
compared to section-2 This could oc-
cur in some recycle services where the
side-stream is actually a recycle flow
with a mass flow around two to five
times the core-flow The side-stream
(recycle) flow is returned from down-
stream of the compressor to be slightly
compressed and recycled to the down-
stream Such a recycled side-stream
compressor can present unique chal-
lenges for design and operation This
kind of machine usually needs very
special operating procedures and very
fine adjustments regarding operating
pressures and flows
Side-Stream Compressor
Performance amp Operation An important consideration is the sen-
sitivity of compressor overall perfor-
mance curve and sectional perfor-
mance curves to the flow ratio (ratio
of side-stream flow to core-flow) and
to the inlet conditions Variations in
the flow and pressure of the main
suction and side-stream inlet should
be controlled within tight tolerances
For compressors with side-stream the ASME PTC-10 code stipulates limits on
flow ratio (side-stream volume to core-
flow volume) The acceptable variation
in volume flow ratio in a compressor
with a side-stream is +-5 percent as
per ASME PTC code The requested
side-stream pressure tolerance is not
usually specified in compressor codes
but it should be around +- 2 percent
(or sometimes +- 25 percent)
Variance in flow ratio impacts the
velocity levels where the two streams
merge Significant variation in the ve-
locity profile upstream of the impeller
changes the incidence on the blade
leading edge of the following impel-
ler This change in incidence leads to a
change in sectional performance over-
all compressor performance and train
efficiency
If the flow ratio is varied between 95
percent and 105 percent (tolerances
specified in the ASME PTC-10 code)
the flange pressure changes accord-
ingly resulting in a change in the sec-
tional performance and overall perfor-
mance The sectional efficiency varies
sometimes more than +- 4 percent
This variance reduces as the flow is de-
creased toward surge However as the
flow is increased toward overload the
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3045wwwflowcontrolnetworkcom January 2015 27
variance increases up to higher values
(even in some cases three to five times
compared to variations near the surge
zone) For example in a case study
for a compressor with side-streams a
+- 5 percent variation in flow ratio and
associated changes (pressures losses
etc) the sectional efficiency reduced by
approximately 34 percent at the rated
flow at allowable operating points at
the end of curve (near the overload
ie choke) efficiency reduced by ap-
proximately 55 percent These results
show that the variation in sectional
performance and overall performance
due to flow ratio is highest at operat-ing points near the overload and low-
est at operating points near the surge
For compressors which work most of
the time at high flow (flow higher than
rated flow and discharge pressure low-
er than rated pressure) the effects of
flow ratio deviations (and subsequently
efficiency reduction) would be higher
than compressors working on the left-
hand side of curve (say with sufficient
margins near the surge)
In the compressor codes (such as
API 617) the compressor power varia-
tions should be maintained below 4
percent However in some applica-
tions clients require tighter tolerances
on the consumed power sometimes
below 2 percent (or even below 15
percent) Some studies suggest while
+- 5 percent of volume flow ratio is
suitable for performance test as per
ASME PTC-10 code some plants re-
quire tighter control on the consumed
power and compressor performance
(lower limits on the efficiency) the tol-
erances on the volume flow ratio could
be tighter than ASME PTC code In this
regard +- 4 percent tolerance can be
suggested on the volume flow ratio (ra-
tio of side-stream flow to core-flow) of
compressors with side-streams
Based on operational experiences
acceptable variations in volume flow
ratio and inlet pressures (suction inlet
and side-stream inlet) of a compressor
with side-streams are +- 4 percent
and +- 2 percent respectively
Another important consideration is
the required adjustments for the flow
ratio (side-stream flow to core-flow)
Compressors with side-stream usually
require fixed side-stream flange pres-
sures For a compressor with some variations in operation conditions (even
small changes) it is not usually pos-
sible to achieve optimum operation by
keeping the flow ratio (side-stream to
core-flow) constant The flow ratio has
to be adjusted according to the inlet
flow at which the machine is operating
in order to get the required correspond-
ing side-stream flange pressure
Thermal changes have also been
known to cause some instability in
centrifugal compressors An example is
the thermal-induced change of resid-
ual unbalance For compressors with
side-streams which feature tempera-
ture differences between core-flow and
side-stream flow the thermal behav-
ior of the compressor is usually more
complex and requires more attention
Heavy Gas ChallengeHeavy gases (such as heavy hydrocar-
bon gases eg propane propylene
MTBE (Methyl Tertiary Butyl Ether))
have very low gas sonic velocities that
produce high Mach numbers in the
aerodynamic flow paths For these
services because of high Mach num-
ber high flow coefficient stages have
very narrow flow maps characterized
by limited surge and choke margins
Compressors with side-streams in
these services present great challeng-
es This is to say the side-streams and
associated mixing further complicate
design operation and performance
prediction because the pressure tem-
perature and flow conditions at each
one of these side-streams as well
as at the exit of the machine require
stringent tolerances to optimize the
overall efficiency and performance
As such it is important to accuratelymodel design operate and moni-
tor performance characteristics of any
impellers diffusers return channels
and generally all flow-path components
in a compressor with side-stream FC
Amin Almasi
is a senior rotating
machine consultant
in Australia He is
a chartered profes- sional engineer of
Engineers Australia
(MIEAust CPEng ndash
Mechanical) and
IMechE (CEng MIMechE) holds
bachelorrsquos and masterrsquos degrees
in Mechanical Engineering and is
a registered professional engineer
in Queensland He specializes in
rotating machines including cen-
trifugal screw and reciprocating
compressors gas turbines steamturbines engines pumps subsea
offshore rotating machines LNG
units condition monitoring and reli-
ability Mr Almasi is an active mem-
ber of Engineers Australia IMechE
ASME and SPE He can be reached
at aminalmasiymailcom
Amin Almasi
Compressor | Gas Flow | Performance Curve | Side-Stream Flow
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3145
The pressure in the stuffing box
containing the packing can be estimat-
ed by the following equation
SBP = [Discharge ndash Suction] 3 + Suction
Pressure at the bottom of the stuff-
ing box will be higher than the suction
pressure but considerably lower than
the discharge pressure It should be
noted this calculation will yield a con-
servative estimate of stuffing box pres-
sure that can be further reduced by
pump design
A hole in the stuffing box serves as
a port for injecting clean fluid that cir-
culates around a lantern ring aligned
under the flush port The fluid flushes
solids back into the process to protect
the packing from abrasive wear If the
clean fluid is injected at a pressure ex-
ceeding that at the bottom of the stuff-
ing box some of it will leak back into
the process and some will leak out to
the atmosphere Recommended flush
injection pressure is 15ndash30 PSI (1ndash2
Bar) greater than the pressure at the
bottom of the stuffing box
Fluid injection is also used to lubri-
cate and cool dry-running packing that
is subject to frictional heat and to pre-
vent air from entering the pump which
reduces flow and operating efficiency
Centrifugal pumps utilize three
types of impellersmdashopen semi-open
and closed (Figures 2 3 amp 4) Open
designs prevent fluids with large solids
from clogging the impellers but at theexpense of pump efficiency Backing
plates on semi-open designs serve to
trap the fluid for more efficient opera-
tion Closed impellers are for use with
clean fluids since solids could ac-
cumulate in the eye which would re-
quire tearing down the pump to remove
them
Single-Stage CentrifugalPumpsSingle-stage centrifugal pumps typi-
cally have good bearing support of the
shaft with few run-out or ldquowhiprdquo prob-
lems However in some cases they
are subject to cavitation This occurs
in the eye of the impeller where the
fluid is under vacuum If the pressure
is low enough it will cause the material
to vaporize forming air or water vapor
bubbles As the fluid passes through
How Pumping Systems Design Affects Sealing Performance
By Chris Boss
8 January 2015
Flow Control Magazine
|
Understanding how different types of pump designs impact
sealing is critical to optimizing efficiency safety and lon-
gevity of the sealing system Used for a wide variety of media
including clear fluids solutions and slurries single-stage
centrifugal pumps are one of the most common
types (Figure 1) Fluid drawn into these pumps
enters the eye of an impeller that spins itto the outside of its container
or volute building pressure as
it moves toward discharge
Some of this fluid will work
its way behind the impeller
where it must be sealed with
compression packing or a
mechanical seal
Figure 1
Figure 2 Figure 3 Figure 4
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3245
the pump under increasing pressure
these bubbles implode sending shock
and vibration through the impeller
adversely affecting the seal This phe-
nomenon can be mitigated by running
the pump at slower speed and higher
pressure at the suction end to prevent
air from entering the fluid
Double-Ended Split-CasePumpsOperating on the same centrifugal prin-
ciple but slightly different geometry are
double-ended split-case pumps (Figure
5) Fluid enters both ends of the pump
and is directed into the eye of an impel-ler which spins it out of the volute to
discharge Packing is installed on both
the shaft and bearing ends so the stuff-
ing box is exposed only to suction pres-
sure which is usually quite low
Axial Flow Pumps Axial flow pumps operate like hydro
turbines in reverse whereby a propeller
(or axial impeller) pushes the fluid to
discharge (Figure 6)
Since the stuffing box is located
downstream of the propeller at the dis-
charge end of the pump the packing is
exposed to the full discharge pressure
Vertical PumpsVertical turbine pumps are typically
flange-mounted on a floor extending
downward into a water-filled sump
hole (Figure 7) Available as single- or
multi-stage pumps they feature an
impeller or series of impellers rotated
simultaneously by a single shaft The
impellers increase the pressure of the
upward flow subjecting the stuffing box
to full discharge pressure
Vertical pumps can be quite long so
inadequate bearing support can cause
the shaft to run out This can induce
undesirable lateral motion on the pack-
ing Worse the packing may be forced
to serve both as a bearing and a seal To
withstand these conditions the packing
should be resilient elastic and resistant
to deformation These properties rule
out packing such as graphite foil in favor
of fiber-based materials
Multi-Stage PumpsMulti-stage pumps are used for high-
pressure applications such as feeding
the boilers in steam-powered generating
plants Stuffing box pressure can vary
with pump design and number of stag-
es Designed for clean fluids and high
operating speeds these pumps typically
have high- and low-pressure ends with ahydraulic pressure equalization line run-
ning between the stuffing boxes
Like vertical pumps multi-stage
pumps feature a series of impellers to
build fluid discharge pressure In the
case of the six-stage pump pictured in
Figure 8 fluid enters at the drive end
where a stuffing box is exposed to suc-
tion pressure Channeled from one
impeller to the next through the pump
casting the fluid can reach extremely
high pressures at discharge
A second stuffing box located at the
bearing end is exposed to an intermedi-
ate pressure from the third impeller This
pressure is greater than the suction pres-
sure but much less than the discharge
pressure which can reach 2000 PSI
Fortunately the stuffing boxes in
these pumps are not exposed to dis-
charge pressures and typically see be-
low 500 PSI which is within the range
of some packing materials
wwwflowcontrolnetworkcom January 2015 29
Figure 5
Figure 6
Figure 7
Figure 8
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 33450 January 2015
Flow Control Magazine
| Gear PumpsPositive-displacement or gear pumps
operate on a different principle than
centrifugal pumps In external gear
pumps the fluid flows around the out-
side of the gears the intermeshing
of which forces it through the pump
to discharge (Figure 9) This design
makes these pumps particularly suit-
able for use with highly viscous fluids
such as resins emulsions syrups and
adhesives As such they are used for
transfer or metering applications
It should be noted gear pumps will
continue to displace fluid as long as
their shafts are turning which can pose
a problem if a clog occurs at the dis-
charge The resulting buildup of pres-
sure can blow out seals and damage
the pump Therefore most gear pumps
have pressure relief valves to divert
fluid back to the suction side for re-
circulation through the pump Internal
gear pumps operate slightly differently
but also have pressure relief valves to
prevent damage from excessive pres-
sure (Figure 10) In both external and
internal gear pumps the maximum
stuffing box pressure is determined by
these valves
Other rotating equipment includes
mixersagitators which are similar to
pumps in terms of the speeds to which
the packing is exposed There are ba-
sically three types of mixersagitators
top- bottom- and side-entry Top-entry
models are subject to the same con-
cerns about shaft run-out ldquowhiprdquo and
lateral forces on the paddles that are
encountered in some vertical pumps
Although some fluid may splash onto
the packing these mixers basically run
dry so the packing must have the abil-
ity to dissipate the resulting frictional
heat
In bottom-entry mixers the packing
is always exposed to fluid and may also
be exposed to solids requiring abra-
sion-resistance If the seal fails the en-
tire contents of the tank will eventually
drain out onto the bearings the floor
and other components under the stuff-
ing box
The packing in side-entry mixers may
be fully or intermittently exposed to flu-
id as well as side loading and vibration
Aside from media temperature
speed and other application variables
the configurations and operating prin-
ciples of rotary-type pumps exert differ-
ent forces on the seals used to keep
them from leaking These forces can
spell the difference between accept-
able seal performance and failure
Understanding these differences has
important implications that should be
taken into account to assure proper
sealing selection for long-term trou-
ble-free performance FC
wwwgarlockcom
Chris Boss is
a senior applica-
tions engineer for
Garlock Sealing
Technologies in
Palmyra NY He
has held various
positions in produc-
tion engineering
product development and applica-
tions engineering for the companyrsquos
compression packing division He
is a BSME graduate of the State
University of New York at Buffalo Mr
Boss can be reached at 800 448-
6688 or chrisbossgarlockcom
Chris Boss
Cavitation | Centrifugal Pump | Pump Packing | Sealing System
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Figure 9
Figure 10
Aside from media temperature speed and
other application variables the configurations
and operating principles of rotary-type
pumps exert different forces on the seals used
to keep them from leaking These forces can
spell the difference between acceptable seal
performance and failure
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3445
NS IDERNDUSTRIAL AUTOMATION + PROCESS CONTROL
WANT
INFORMATION
ON THE
automationindustry
SUBSCRIBE NOW at wwwiainsidercouk
Published by Spitzer and Boyes LLC Write in 15 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3545
Frost says the push from developing
economies is important as the market
is technologically mature and seeing
restricted growth in developed econo-
mies This is particularly true in Europe
and North America where recent finan-
cial insta-
bility has
reduced capital expenditure across end-
user industries
Bill Moore senior vice president of
sales development and channel man-
agement for global bearings manufac-
turer SKF says ldquosmartrdquo products and
the expansion of robust reliability pro-
grams are helping to drive new invest-
ment particularly in developed coun-
tries where the cost to compete is
high Frost says the magnitude of
the existing global installed base will
strengthen the need for replacement
and upgrades adding to market de-
mand as well
Frost says despite the potential
in developing economies the focus
on price as a product differentiator
may lead to intense price pressures
among manufacturers and bring down
the value of the overall market in the
short term The growing trend among
consumers to choose low-cost Chinese
imports will complicate this challenge
As price and quality become stan-
dardized across the globe customers
will base more of their purchasing deci-
sions on value-added services accord-
ing to Frost This will push manufactur-
ers to create more maintenance-free
solutions such as lubrication-free
bearings that offer end-users savings
on service and replacement costs and
reduce downtimeldquoOffering a complete line of prod-
ucts with comprehensive services will
be another feather in the cap of ven-
dors looking to widen their consumer
baserdquo notes Frost Industrial Automa-
tion and Process Control Research
Analyst Guru Mahesh
Moore says the trend of outsourcing
manufacturing to regions where labor
and production costs are favorable is
becoming less of a factor
ldquoThe days when cheap labor made
a significant difference in where a prod-
uct is manufactured mdash particularly high
value-added products or high weight
and bulk products mdash are coming to
an end as the cost of transportation
storage and inventory balance out the
benefits of production costs where la-
bor is a smaller percentage of the cost
of manufacturingrdquo Moore says ldquoLocal
manufacturing development will indeed
come to developing countries as their
ability to create markets that generate
economies of scale that support local
production is a clear trend and one that
all manufacturers will pay attention tordquo
Moore says that development of
maintenance-free or predictive tech-
nologies and products will be a sig-
nificant advantage to everyone in the
Bearing amp Coupling Manufacturers Focus
onDEVELOPING Economies
amp EFFICIENCY InnovationBy Amy W Richardson
2 January 2015
Flow Control Magazine
|
gy
Anew study from Frost amp Sullivan (wwwfrostcom) fore-
casts steady growth for the overall bearings and couplings
market based on rapid industrial development in high-growth
regions Specifically Frost predicts development in Mexico
Indonesia Nigeria Turkey Brazil Russia India and Chinawill help boost the bearings amp couplings market from $2206
billion in 2013 to an estimated $2676 billion in 2018
The development of maintenance-freeor predictive technologies will helpboost growth in the bearings market For example SKF is developing products that will automatically notifyusers when a bearing or mechanicalrotating component is approachingthe end of its useful life Pictured hereis an SKF Microlog analyzer a por- table condition monitoring tool
COURTESY SKF
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
improved productivity through simplified solutions The powerful technology and tools ensure repeatable
reliable accurate measurements Easier access to process data allows for better troubleshooting process
optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
For daily product notes visit the lsquoFeatured Productsrsquo section flowcontrolnetworkcom
ON THE WEB
1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3845
FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
and benefits as well as grids of
instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
services provided for the
mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
Brought to you by Beamex
Your Source For Fluid Handling Videos
Go towwwflowcontrolnetworkcomfreeinfo
Select appropriate issue ofFlow Control Magazine
Select advertisements thatinterest you
Enter your email amp clickldquoSubmit Requestrdquo
1
2
3
4
PRODUCT
INFORMATION
ONLINE
Follow these 4 steps to receive freeproduct information from suppliers
FREE
FEATURED VIDEO How to Calibrate aPressure Measurement Loop
For more information about FlowTube
sponsor packs email FlowControlGrandViewMediacom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4245
THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
Name ________________________________________________________________
Title _________________________________________________________________
Company _____________________________________________________________
AddressCityStateZip __________________________________________________
______________________________________________________________________
Phone ________________________________________________________________
E-Mail ________________________________________________________________
One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545
![Page 13: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/13.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1345
HE OUTLOOK | News amp Notes
10 | January 2015
Flow Control Magazine
Hydraulic Fracturing WaterTreatment amp Reuse Expected to Soar
Wastewater treatment spending for
hydraulic fracturing is expected to
grow almost three-fold from $138 mil-
lion in 2014 to $357 million in 2020 in
the US according to a new report from
Bluefield Research
The US hydraulic fracturing industry
consumes over 1 billion barrels of wa-
ter annually producing 450ndash500 mil-
lion barrels of contaminated water for
disposal with only about 14 percent
treated and reused Bluefield cites watersupplies increasingly at risk tighter regu-
lations emerging in key states and costs
of disposal on the rise as factors con-
tributing to the substantial rise in water
treatment and reuse which is expected
to account for 27 percent of total pro-
duced and flowback water by 2020
Overall the US hydraulic fracturing
industry will spend $638 billion in 2014
on water management Water transport
and disposal costs will account for 66
percent of the total water managementspent this year with treatment compris-
ing roughly 2 percent
Bluefield reports water scarcity in
Western US states has had little im-
pact to date on fracturing water supply
but that is likely to change if droughts
persist Meanwhile state regulators are
beginning to tighten control of produced
water disposal In Pennsylvania where
policymakers in 2010 placed discharge
limits on wastewater from unconven-
tional oil amp gas operations statewide
treatment and reuse rates for the Mar-
cellus jumped to 90 percent in 2014
The increasing cost of transport and
injecting water into wells mdash now ac-
counting for 66 percent of water servicesspending mdash and the improving cost
structures of treatment provide another
driver of reuse Bluefield reports Well
operators that employ treatment and re-
use solutions spend on average $880
per barrel of water used compared to
$1020 per barrel of water trucked and
injected into wells although cost com-
parisons are site specific
ldquoFracking has been the Wild West for
the US water industryrdquo said Reese Tis-
dale president of Bluefield Research ina prepared statement ldquoThere are three
reasons for this first there has been
an explosive build-out of fracking well
installations now surpassing 126000
Second there has been a lack of clear
regulation on water management in key
markets And third there is not a one-
size-fits-all treatment solution for frack-
ing meaning solutions providers have
had to ascend a steep learning curve
to treat the variable wastewaters that a
single well is capable of producingrdquo
Tisdale notes that these inhibitors
while still acute are beginning to take on
a new form This is partially due to signifi-
cant gains in water management experi-
ence realized adoption of more efficientwater management strategies among
well operators and the emergence of
new policy mechanisms from regulators
that are playing catch-up with the fast-
moving hydraulic fracturing industry
trendlines
Treatment2
Disposal
6
Supply10
Storage22
Transport60
US $638Billion
S O U R C E B L U E F I E L D R
E S E A R C H
Write in 23 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
Industry-Leading
Warranties
Temperature Measurement Solutions
bull Probe type industrial RTDsbull Electronic temperature switchtransmitter bull Vapor-actuated remote thermometersbull Digital temperature indicatorsbull Platinum resistance temperature transmitterbull Compact OEM temperature transmitter bull Industrial amp instrument type bimetal thermometersbull Thermowells
1010 West Bagley Road I Berea Ohio 44017 I P 4402430888 I F 4402433472wwwnoshokcom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1445
New Technique Could ReduceEnergy Required for Oil Refinement
UK scientists have developed a
technique they say has the poten-
tial to dramatically reduce the amount
of energy required for the refinement
of crude oil
Professor Martin Schroumlder and Dr
Sihai Yang from The University of Not-
tingham (wwwnottinghamacuk ) have
led a multi-disciplinary team of scien-
tists from Nottingham the Science and
Technology Facilities Councilrsquos (STFC)
ISIS Neutron Facility Oak Ridge Na-tional Laboratory and Diamond Light
Source to discover a porous material
that works like a chemical sponge to
separate a number of important gases
from mixtures generated during crude
oil refinement
According to a news release from
The University of Nottingham the ex-
isting industrial process uses ldquohuge
amounts of energy to separate and pu-
rify these gases so the new technique
has the potential to revolutionize the oil
industry by significantly reducing car-
bon emissions and making the process
more environmentally friendlyrdquo
Commercially UsefulCrude oil is a raw material that is
refined to produce fuel for cars toheat homes and to create polymers
and other useful materials It is made
up of a complex mixture of hydro-
carbons (chemical compounds that
contain only hydrogen and carbon) of
which certain components are espe-
cially commercially useful
One industrial process used to
achieve hydrocarbon separation is
called ldquocryogenic distillationrdquo which is
widely used worldwide and uses vast
amounts of energy to generate the high
pressures and cryogenic temperatures
required to ensure efficient separation
research amp development
wwwflowcontrolnetworkcom January 2015 | 11
PLASTIC CONTROL VALVES FORALL YOUR CORROSIVE APPLICATIONS
PO Box 938 bull Angleton TX 77516Tel (979) 849-8266 bull wwwcollinsinstcom
Collins plastic control valves are
highly responsive control valves
designed for use with corrosive
media andor corrosive atmos-
pheres
Collins valves feature all-plastic
construction with bodies in PVDF
PP PVC and Halar in various body
styles from 12 - 2 with Globe
Angle or Corner configurations and
many trim sizes and materials
Valves may be furnished without
positioner for ON-OFF applications
Call for more information on our
plastic control valves
Write in 9 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1545
of hydrocarbon mixtures into pure components
However researchers say an innovative solution may
have come in the form of a novel chemical sponge This
porous material a metal-organic framework was devel-
oped by the same team at Nottingham just two years ago
Now in research published in Nature Chemistry for the
first time scientists have proven that it can be used toseparate hydrocarbon mixtures without the need for high
process pressures or very low process temperatures
Reusable MaterialsMade from cheap organic materials aluminum nitrate
salt and water the porous material called NOTT-300 is
able to adsorb different gases found in mixtures of hydro-
carbons at different rates making it possible to sepa-
rate them and extract the most useful ones NOTT-300
requires less energy to function than existing methods
as it operates at ambient temperatures and normal pres-
sures researchers say The gases that are adsorbed intoNOTT-300 can be removed without a significant energy
input and therefore the material can be easily reused
The team of scientists from Nottingham used Diamond
the UKrsquos synchrotron science facility as well as STFCrsquos
ISIS Neutron Facility and Oak Ridge National Laboratory
the UKrsquos and USArsquos world-leading neutron facilities re-
spectively to prove that the sponge works under real-life
conditions
Professor Martin Schroumlder Dean of the Faculty of Sci-
ence at Nottingham said in the news release ldquoIt is a very
important to be able to separate different hydrocarbons ef-
fectively and efficiently with low-energy consumption Po-rous solids such as the metal-organic framework system
studied here represent important materials for the future
development of low-energy separation technologies We
are most grateful to our collaborators at ISIS Neutron Fa-
cility Oak Ridge National Laboratory and Diamond Light
Source in bringing this work to fruitionrdquo
Significant Impact on Oil IndustryDr Sihai Yang the winner of Diamond Young Scientist
and BTM Willis Prize is a Senior Research Fellow at
Nottingham He led the project together with Professor
Martin Schroumlder Yang said ldquoWith the help of advancedcentral facilities like Diamond ISIS and ORNL we have
developed a new separation technique which can poten-
tially reduce the energy usage associated with oil petro-
leum and chemical industries which require the separa-
tion of raw hydrocarbons from crude oil
The discovery of the new material NOTT-300 could
have a significant impact on the oil industry by removing
the necessity for some energy-intensive refinement pro-
cesses researchers say
The research was funded by Engineering and Physical
Sciences Research Council (EPSRC) the European Re-
search Council (ERC) The University of Nottingham andLeverhulme Trust
12 | January 2015
Flow Control Magazine
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THE OUTLOOK | News amp Notes
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1645
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 174514 | January 2015 Flow Control Magazine
PPLICATIONS CORNER | Process Instrumentation
This is the final article in a series based on the troubleshoot-
ing of a mysterious unit shutdown due to flowmeter perfor-
mance problems
If yoursquove followed this column for most of 2014 you know
that what should have been a liquid ammonia stream to the
feed plant became problematic due to the occurrence of
bubbles of ammonia gas These bubbles caused an ultrasonic
flowmeter in a unit to indicate zero flow and caused the reactor
to scram (shut down) under warm operating conditions The source of the bubbles was traced back to the pres-
sure drop associated with a control valve located at the
exit of the liquid ammonia tank farm
This issue was resolved by identifying the problem
and fixing it at its source This was a pragmatic ap-
proach at the time (early 1980s) given the operation
of the cooling system in the unit and the limited selec-
tion of applicable flowmeter technologies
By the early 1990s changes were implemented that elim-
inated all process cooling requirementsmdashexcept for the small
jacketed cooler upstream of the liquid ammonia flowmeter In
other words after these changes the entire cooling system
would be operated and maintained to cool a few meters of
one small ammonia pipe Coincidently at about the same
time Coriolis mass flowmeters became more mature and
could reasonably measure the mass flow of liquid streams
with homogeneous low levels of vapor
The convergence of these two events resulted in another
approach to the problem that was not available in the early
1980smdashie install a Coriolis flowmeter that could operate in
the presence of bubbles The purchase and installation of a
Coriolis mass flowmeter was given high priority given its im-pact on unit operation economics and safety (by eliminating
the ldquomidget-makerrdquo (see March 2014 page 14))
Plant requirements and the technology that can meet
plant needs keep changing An excellent solution today can
become outdated in just a few years However there are few
substitutes for understanding fundamentals when addressing
a problem In other words there can be more than one way
to skin a cat FC
wwwspitzerandboyescom
Problem Solved AgainA Coriolis mass flowmeter provides a better solution
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I d e a l f o r Ag g r e s s i v e C h e m i c a l s
1384 POMPTON AVENUE CEDAR GROVE NEW JERSEY 07009
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bull Rugged thermoplasticshandle corrosive andultra-pure chemicaltreatments
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pump performancebull Prevents overpressure in
piping system
bull Wide range of pressuresettings
bull PTFE shaft and diaphragm designs
bull 1 4rdquo - 3rdquo sizes in PVC CPVC PVDFPolypro and PTFE
bull First State approved
thermoplastic valve for
anti-siphon applications
Write in 10 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
David W Spitzer
Ammonia Gas | Coriolis Flowmeter | David W Spitzer | Scram | Troubleshooting
FLOWSTREAM Find related content flowcontrolnetworkcom
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and Boyes
LLC offering engineering seminars strategic marketingconsulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer can be reached at 845 623-
1830 or at wwwspitzerandboyescom
The purchase and installation of a
Coriolis mass flowmeter was given
high priority given its impact on unit
operation economics and safetyldquordquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1845
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Beyond Control The NEW Research Controlreg SRD positioner does
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plus more The SRDrsquos comprehensive diagnostics tool
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1945
Process improvements to increase yield or cut manufactur-
ing costs typically require enhanced process control but the
installed base of measurement instrumentation in a process
plant may simply be unable to facilitate improvements because
of age inadequate performance or unreliability Maintenance
cost and unscheduled process downtime for an aging process
plant can be very damaging to the balance sheet Upgrading
to new more accurate and more reliable instrumentation can
be prohibitively expensive New plant construction must alsomaintain a focus on optimizing costs for the process control
infrastructure The budget approval decision for new plant
construction must weigh such costs against projected market
conditions for the products that the plant is intended to manu-facture In todayrsquos volatile global marketplace return on invest-
ment calculations for plant upgrade or new plant construction
projects may go through several iterations before the trigger is
finally pulled or indeed not pulled
This article describes advances in two-wire instrumenta-
tion specifically in relation to flowmeters that have taken
place in the past few years and the significant cost benefits
that this new technology can realize for plant builders and op-
erators in terms of capital investment and cost of ownership
The Significance of Two-Wire Loop Power
A survey involving 204 participants in the chemical indus-try across Germany Switzerland the UK Canada and the
United States (Manfred Koenig PhD KIM Ludwigshafen
Germany 2006) revealed an 87 percent preference for two-
wire instrumentation versus four-wire in process applications
and 89 percent for utilities This overwhelming preference
may stem from the fact that older process plants were built
with two-wire twisted-pair cable networks connecting all
process units and measuring instruments together in an
overall plant control scheme
However these existing cables are relatively unsophisti-
cated and incapable of supporting anything but low-energy
instrumentation that is insensitive to interference from otherelectrical sources that might be sharing the same cable con-
duit Further the low energy levels supported by these two-
wire loops are more easily rendered safe in terms of explo-
sive risk in hazardous areas containing flammable materials
Many older process plants are also likely to have a significant
installed base of flowmeters employing pre-war (pre-1945)
technology such as positive displacement (PD) turbine vari-
able area (VA or Rotameter) and differential pressure (dP)
Market data firm Flow Research Inc (wwwflowresearch
com) indicates collectively a future compound negative annual
growth rate approaching minus 3 percent to 5 percent for PD
turbine and VA flowmeter types while dP is expected to keeppace with market growth (World Market for Flowmeters 2010)
YSTEMS DESIGN | Flow Measurement
16 | January 2015
Flow Control Magazine
The Two-Wire
ADVANTAGENew wiring options enable modern instrumentsto drive cost savings in existing plant systems
By Steve Milford
Advances in two-wire instrumentation have enabled mod- ern technology to be employed to the advantage of older
plant and process systems
Some chemical manufacturing plants are
competing for survival not only externally
against other global companies but also
internally among the global facilities of theirown company Other industry sectors face
similar challenges
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2045wwwflowcontrolnetworkcom January 2015 | 17
The Need to Replace Older TechnologiesUntil the 21st century two-wire loops were only able
to support these relatively unsophisticated instruments
which convert their measurement by various means into a
4-20mA output or pulse signal to the control system The
more advanced post-war flowmeter technologies such as
Coriolis ultrasonic or electromagnetic flowmeters have
until just eight years ago required a dedicated power sup-
ply for their function in addition to the output loop and
thus a four-wire infrastructure was required as a minimum
Therefore upgrading older two-wire meter devices to moremodern four-wire technology could require significant
expenditure in terms of the installation of separate power
cables and supply modules
There was a major breakthrough in 2006 when a true
two-wire loop-powered inline liquid ultrasonic flowmeter
was introduced (Figure 1) The nature of this breakthrough
was innovation in device power management This was the
missing piece up to that point because to be a true loop-
powered device the meter had to directly provide a full 16
mA span using less than 36 mA of remaining loop current
and less than 1 Watt of electrical energy The flowmeter
operated on a single 4-20 mA HART two-wire loop wasremotely powered by a DC supply was certified Class 1 Divi-
sion 1 and could be deployed as Intrinsically Safe through
the use of an approved safety barrier
A true two-wire loop-powered Coriolis flowmeter followed
in 2011 (Figure 2) employing a new and more advanced
common electronics platform A two-wire loop-powered inline
ultrasonic flowmeter for low-pressure gas was introduced in
2012 and a second two-wire loop-powered Coriolis meter fol-
lowed in 2013 offering improved measurement performance
and an additional high-performance meter tube material
Electromagnetic and vortex flowmeters had already been
available for some years in two-wire loop-powered form butimproved performance resulted as these designs were incor-
COURTESYENDRESS+HAUSER
Figure 1 A two-wire ultrasonic flow- meter released in 2006 operated ona single 4-20 mA two-wire loop
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I I I I LL I
I I I I LL I
copy COPYRIGHT 2015 OMEGA ENGINEERING INC ALL RIGHTS RESERVED
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Prices listed are those in effect at the time of publication and are subject to change without noticePlease contact OMEGArsquos sales department for current prices
FPD3000 SeriesStarts at$630
FPD3300 SeriesStarts at
$790
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OSXL-TIM3$999
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Positive Displacement Flow Meterfor Fuels and Oils
bull Aluminum Bodybull FKM Sealsbull Temperatures up to
80ordmC (176ordmF)bull NPT or BSP Threadsbull DIN JIS or ANSI
Connection (Availableon 1 and Larger Sizes)
Positive DisplacementFlow Meter for Solvents
Thermal Imaging CameraFor Inspection andFactory Diagnosis
Note Not for ExportUSA Only
Your One-StopSource for Process
Measurement and Control
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 214518 | January 2015
Flow Control Magazine
porated into their new common electron-
ics platform in 2013 So all the ldquomodernrdquo
flow measurement technologies mdash that
is to say those introduced post-war mdash
have become available as two-wire loop-
powered devices with one exception
namely thermal mass (thermal disper-
sion) meters Unfortunately the power
requirements for this technology exceed
what is currently deemed possible withtwo-wire loop-power management
Payback forTechnology UpgradeConsider a 1rdquo process line
containing a liquid process
ingredient costing $1lb at a
mass flowrate of 150 lbmin-
ute We have $150minute
flowing in the line translating
to $9000hour and $72000
per eight-hour shift That cal-culates further to $360000
per five-day working week and
for a working year of 40 weeks for
example that is $144 million Assume
the existing device is a turbine flowmeter
Now imagine a two-wire loop-
powered Coriolis mass flowmeter is
installed in place of the existing meter
The line would need to be drained and
probably one process flange replaced
allowing the Coriolis to fit mechanically
in place of the turbine However thetwo-wire loop already used for carrying
the existing meterrsquos flow signal to the
control room can be used unaltered
for the complete electrical installation
aspects of the Coriolis flowmeter
The upside of the change is signifi-
cant and clear cut Assuming the exist-
ing meter measurement uncertainty was02 percent of reading then measure-
ment uncertainty improves through use
of Coriolis to 01 percent of reading
giving a 01100 x $14400000 im-
provement in control of the ingredient
annually or $14400 A two-wire Coriolis
mass flowmeter with 01 percent mass
flow accuracy would be paid for in ap-
proximately 6-8 months In practice the
improvement in measurement uncer-
tainty would be greater as the operator
would gain temperature and density in-formation from the Coriolis and the mea-
surement would be devoid of any fluid
property dependence Viscosity change
for example can have a major impact on
turbine meter performance Mechanical
wear and tear that turbine meters even-
tually experience which causes them to
under-register flow is precluded by mod-
ern devices like Coriolis
Furthermore if the process ingredient
was being blended with another then ad-
ditional process improvements could berealized through in-line blending control
using Coriolis technology for final density
as the control point It is possible to have
dual 4-20 mA outputs from two-wire
loop-powered meters but as the main
4-20 mA output representing the prima-
ry variable is also HART then an external
HART Loop Converter or HART IO card in
the control system can provide second-
ary tertiary and quaternary variables as
4-20 mA signals A Coriolis meter is trulya multi-variable device Certain two-wire
devices are also available with Profibus
or Foundation Fieldbus communication
Cutting Wiring CostsIn 2003 WIBEXERA (International
Instrument Usersrsquo Associations) Report
T 2732 X 03 was published and it pro- vided an average survey of prices quoted
in projects at that time for the provision
of power supplies for four-wire instru-
ments The price ranged from euro1200
to euro1800 per instrument depending
upon design and plant characteristics
for an average cost of euro1500 (about
$2000) It would be reasonable to
assume an inflationary factor of 2 per-
cent per annum giving an approximate
current-day figure of $2500
From another source within thechemical industry an estimation of
$40foot to $50foot was given for in-
stallation of four-wire cabling For a
linear 50-foot cable run with for ex-
ample a 10-foot vertical at each end
this equates to $3150 Actual costs
and budget estimates have been given
as high as $10000
The Extent of the Opportunity The modern post-war flow measure-
ment technologies have different powerrequirements and consequently they
are not all available for the
same size range in two-wire
loop-power form For example
two-wire Coriolis flowmeters
are limited to 2rdquo diameter
electromagnetic and inline
low-pressure gas ultrasonics
are limited to 8rdquo and vortex
and inline liquid ultrasonic are
limited to 12rdquo
Nevertheless for thechemical industry in particu-
lar perhaps two-thirds of the
process pipes in a plant will be no larger
than 2rdquo and even when the host process
pipe is larger a correctly sized flowmeter
can still be less than 2rdquo There is consid-
erable scope for two-wire loop-power to
deliver value for flow measurement ap-
plications with total safety
The virtues of Coriolis technology
have been covered but what about
other two-wire technologies An elec-tromagnetic flowmeter in two-wire form
YSTEMS DESIGN | Flow Measurement
In todayrsquos volatile global mar-
ketplace return on investment
calculations for plant upgrade or
new plant construction projects
may go through several itera-
tions before the trigger is finally
pulled or indeed not pulled
ldquo
rdquo
COURTESYENDRESS+HAUSER
Figure 2 Two-wire Coriolis flowme- ters became available in 2011
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2245
can be used on water wastewater or
a light water-based slurry provided the
fluid has around a 20 microSeimenscenti-
metre (microScm) electrical conductivity
A magnetic flowmeter is full bore un-
less flowrates dictate a reduced meter
size in the interests of performance and
so there are no intrusions into the flow
stream and no pressure loss An accu-
racy of 05 percent of reading is normal
from a two-wire magnetic meter and a
modest five diameters (5D) of straight in-let run is needed to avoid error from up-
stream flow disturbances When the fluid
exhibits insufficient conductivity then
the same performance and installation
requirements can be met by an inline ul-
trasonic flowmeter provided the liquid is
essentially clean and bubble-free
For gas or steam applications a vor-
tex meter is the normal choice Using a
built-in temperature sensor a two-wire
loop-powered vortex meter can calculate
mass flow of saturated steam using in-ternal steam tables An external pressure
input allows mass flow of steam to be ac-
curately calculated even when saturated
steam becomes superheated as can oc-
cur downstream of a pressure regulating
valve With mass flow known the vortex
meter can calculate energy and heat flow
A new and exciting development is
the ability of the vortex meter to indicate
wet steam and calculate dryness frac-
tion or steam quality For safety and ef-
ficiency saturated steam should be dry
and free from condensate that is to say
it should possess a high steam quality
factor However the dry or wet state of
saturated steam can sit on a knife-edge
and shift to the opposing state due to
the slightest change in process condi-
tions Rapid and reliable indication of
this change of state is now available
Perhaps the most astonishingachievement in the power management
of two-wire loop-power flowmeters is
that of the ultrasonic biogas meter It is
now possible not only to measure the
flow of wet dirty variable composition
and low-pressure anaerobic digester
gas landfill gas and coal bed methane
gas with a two-wire loop-powered ultra-
sonic flowmeter but also the same de-
vice uses an inbuilt temperature sensor
in combination with measured sound
velocity to calculate methane contentcalorific value and energy flow
Technology to Take UsForwardModern flow technologies provide instru-
ment engineers with vital self-monitoring
information The format of such infor-
mation is easier to understand and act
upon when presented in accordance
with harmonized international guidelines
for online plant asset management eg
NAMUR Standard 107
Continuous plain-text self-diagnostic
and process-related information with
suggested remedies (Figure 3) make it
possible for instrument engineers andoperators to take action at the appro-
priate time mdash immediately or during
the next scheduled shutdown mdash saving
time and money by knowing the exact
health of their measuring point and the
probable actions required to rectify any
abnormal conditions Device verifica-
tion offering third-party validated trace-
ability can be performed on demand ei-
ther locally or remotely from the control
room without the expense of a man in
the field Calibration is then avoided ordeferred without process interruption
Where a process plant has a large
installed base of older mechanical tech-
nologies the decision to embark upon a
program of replacement for plant mod-
ernization cannot of course be taken
easily There are the stocks of spare
parts to consider along with the plant
instrument technicians who are trained
on and at ease with the old devices
However a process plant that retains
the older technology going forward willbe at risk and may find it increasingly
difficult or even impossible to maintain
a cost position that competes effective-
ly in the global market FC
wwwusendresscom
wwwflowcontrolnetworkcom January 2015 | 19
Steve Milford
is a Flow Product
Business Manager
for Endress+Hauser
Inc in Greenwood
Ind He has been
involved in flow
measurement since
1983 and has been
actively involved with standards devel-
opment for flow technology within the
International Standards Organization
(ISO) and the British Standards
Institute Mr Milford can be reached
at stevemilfordusendresscom
Steve Milford
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Coriolis Flowmeter | Magnetic Flowmeter | Two-Wire | Ultrasonic Flowmeter | Vortex Flowmeter
Figure 3 A modern instrumentrsquos display module can provide continuous plain- text self-diagnostic and process-related information
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2345
The bottom line is the volume of gas under one set of
pressure and temperature conditions is not the same as it
would be for the gas under different conditions Why is thisimportant Without compensation for compressibility read-
ings taken by gas flowmeters can result in measurementsmdash
and costs to the buyermdashsignificantly lower or higher than they
should be
The flow of gas in a system can be accounted for and
reported in a number of ways such as by volume by mass
flowrate and by energy Inline turbine meters can offer both
reliability and accuracy in measuring gas flow when matched
with a monitor capable of calculating and displaying results
that have been adjusted for the nature of the gas and impor-
tantly the pressure and temperature
Measuring Flow with an Inline TurbineFlowmeter
With an inline turbine meter gas flows into the meter through
a length of piping that helps to pre-condition the flow by
reducing undesirable swirls and asymmetry Where consid-
ered necessary a flow straightener may even be installed in
line to create a uniform flow profile to the extent possible
As can be seen in Figure 1 a rotor support within the tur-
bine housing further conditions the flow and directs it through
the blades of the rotor High-precision ball bearings allow the
rotor to freely rotate on the shaft
The rotorrsquos rotational speed is directly proportional to the velocity of the fluid passing through the meter The rotor itself
incorporates magnets (or magnetic blades depending on thedesign) while the housing is non-magnetic
A proximity sensor (also known as a pickup coil) is located
in line with the rotor and detects the electrical pulses gener-
ated by the ferrous rotor spinning through the magnetic field
Each pulse represents a discrete volume of gas The out-
put frequency provides the indication of the gas flow rate and
the accumulated pulses over a specified time represent the
total volume of fluid for that measurement period
Need for Calibration The flowrate of the gas through the meter cannot be deter-
mined accurately unless the meter is calibrated The fac-tory calibration determines the meterrsquos constant known
as a K-factor which is then inputted into the gas monitor
PPLICATION NOTES | Flow Measurement
20 | January 2015
Flow Control Magazine
COMPENSATING for
Compressibility inMeasuring Gas Flow Why K-factor adjustment is essential foraccurate inline turbine flow measurement
Unlike crude oil and other liquid fossilfuels natural gas poses a challenge
in monitoring the quantity of gas flowing
through pipelines While liquids do not com-
press gases do and the mass flowrate of
gas being transmitted through gathering
lines depends on both the pressure and
temperature
By Kevin Clark
Figure 1 Internal components of a liquid turbine flowmeter
C O U R T E S Y
T U R B I N E S
I N C
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2445
Wondering Whether the
Pump Guy Seminar
Is for YouCheck out the ldquoPump Guy Insightsrdquo
video series flwctrlcompginsights
PUMP GUY INSIGHT 1NPSHa vs NPSHrmdashWhy all pumps need gauges
PUMP GUY INSIGHT 3How to Operate Your Pump at Best Efficiency
PUMP GUY INSIGHT 5Head vs Flow
PUMP GUY INSIGHT 2 Your Pumps Are Constantly Moving On Their Curves
PUMP GUY INSIGHT 4 The Role of the Pump Reliability Chain
PUMP GUY INSIGHT 6How to Read a Pump Curve
PARTNER SPONSORSFor more information and to register
for upcoming Pump Guy Seminars
visit FlowControlNetworkcomPumpGuy
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2545
PPLICATION NOTES | Flow Measurement
22 | January 2015
Flow Control Magazine
Gas flowmeters measure the actual volume of gas passing
through the meter per minute irrespective of pressure and
temperature1
The volumetric flowrate of a gas is often corrected to
ldquostandardizedrdquo conditions of pressure and temperature While
ldquostandardrdquo conditions can vary depending on the definition
in the US this typically means a pressure of 1473 PSIA(pounds per square inch absolute) and a temperature of 60 F
The flowrate measurement is reported in standard cubic feet
per minute (SCFM)
Compensating for changes in pressure and temperature is
critical Consider a meter system setup for flowing conditions
of 60 PSIG (pounds per square inch gauge) and 60 F and the
line pressure decreases to 50 PSIG while the temperature
remains constant The difference in SCFM between the two
is more than 15 percent which would cost the buyer more
for the gas than it should As Table 1 demonstrates even a
small variation in pressure will result in a surprisingly high er-
ror percentage
Automation of the K-Factor The K-factor is established by an initial factory calibration In
the case of a non-compensated flow monitor any variations
in pressure and temperature will result in manual adjust-
ments needed to the K-factor In order to maintain accurate
flow measurement users must monitor pressure and temper-
ature and make corresponding adjustments to the K-factor To eliminate these manual adjustments some suppliers offer
a flow monitor that automatically adjusts for any changes in
pressure and temperature
These monitors provide accurate flow measurement regard-
less of changing environmental conditions in some cases sup-
porting applications with pressures as high as 15000 PSIG and
temperatures between -350 F to 350 F with a standard accura-
cy of +-1 percent over a flow range of 05 ACFM to 650 ACFM
Final NotesDuring the operation of a flowmeter system the ability to obtain
a readout mdash and to adjust for line pressure and temperaturechanges mdash is sometimes compromised by a lack of electric
power This issue is especially true along gas pipelines in remote
areas To overcome this limitation some manufacturers have
designed low-powered flow monitors which can operate for up
to on year on a single lithium D-cell battery
It is important for users to recognize the effects of the
compressibility of gas As such the quantity of a gas flow-
ing through a gas flowmeter depends on the pressure and
temperature In order to ensure accuracy any flowmetering
system must employ a means to correct for these effects
Otherwise the readout is certain to be in error and could be
unnecessarily costing money This is particularly crucial onwellhead production and in billing scenarios FC
wwwturbinesincorporatedcom
Notations1 The measurement factor in the US is known as the
ACFM actual cubic feet per minute (Metric units are typically
ACMH actual cubic meters per hour)
Table 1 Error induced by line pressure changes
Constant Temperature with Varying Pressure
Pressure Temperature PulsesSCF Error
50 60 2556027821 1546
51 60 2517123288 1370
52 60 2479385307 1199
53 60 2442762186 1034
54 60 240720524 873
55 60 237266858 717
56 60 2339108911 566
57 60 2306485356 418
58 60 2274759285 275
59 60 2243894166 136
60 60 2213855422 000
61 60 2184610304 132
62 60 2156127771 261
63 60 2128378378 386
64 60 210133418 508
65 60 2074968632 627
66 60 2049256506 743
67 60 2024173807 857
68 60 1999697703 967
69 60 1975806452 1075
70 60 1952479339 1181 Flow Measurement | K-Factor | Measurement
Accuracy | Turbine Flowmeter
Find related content flowcontrolnetworkcomhellipSearch on
FLOWSTREAM
Kevin Clark is senior develop-
ment engineer for Turbines Research
amp Development LLC Turbine RampD is a
subsidiary and the research and techni-
cal support arm of Turbines Inc which
serves a range of industries and applica-
tions from oil amp gas to cryogenic liquids
to custody transferKevin Clark
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2645
Pumps Bearings amp Seals TECHNOLOGY REPORT
FEATURES
SYSTEMS DESIGN
The ComplicatedCase of
Compressors
withSide-Streams
24 28 32BEST PRACTICES
How PumpingSystems
AffectSealing
Performance
TECH OUTLOOK
BearingSuppliers
Drive Gains InDeveloping
Markets
wwwflowcontrolnetworkcom January 2015 | 23
S P E C I AL S E C T I O N
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2745
The design and operation of compressors with side-
streams has always been difficult because flow entering the
compressor needs to be mixed with the core flow already
in the compressor (compressed in section-1) in a manner
that does not degrade the aerodynamic performance of sur-
rounding sections Minimizing losses and ensuring proper
mixing of the side-stream flow and core-flow are required to
ensure effective performance of a compressor of this sort
Key considerations for an application involving compres-
sors with side-stream flow include
The plant process typically dictates the side-stream
flange pressure
The impellers upstream of the side-stream should
achieve the necessary pressure for the core-flow
The side-stream flow is typically at a temperature dif-
ferent from compressor core-flow temperature
Process plants need some degree of operational flex-
ibility ie the ability to support variations in core-flow condi-
tions and side-stream conditions
Modern process plants are usually specifying more than
one operating conditions (sometimes two or more manda-
tory conditions) which can present challenges to compres-
sors with side-streams Adding to these issues modern
compressors should operate with much higher impeller tip
The COMPLICATED CASE ofCompressors with Side-StreamsConsidering key system design requirements
to ensure operational efficiency By Amin Almasi
4 January 2015
Flow Control Magazine
|
y
g
Some compressors in certain applications
have one or more incoming side-streams
(or side-loads) that introduce side-stream
flow to mix with the core flow In other words
a radial side-stream inlet is utilized in multi-
impeller centrifugal compressors to introduce
additional gas into the mid-stage of a com-
pressor This design enables optimization in
some process plants However the flow dis-
tribution after the junction of the side-stream
and the main return channel of the upstream
section can significantly affect the perfor-mance of the next section of compressor
In most cases the pressure levels at these
side-streams should be accurately predicted
to meet the theoretical performance
Compressor station at a natural gas processing plant
R U D M E R Z W E R V E R I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2845
speeds and inlet Mach numbers compared to previous
generations of compressor technology
Likewise side-streams are now com-
monly used with medium-sized and
large-sized compressors (eg 1ndash60
MW) The costs associated with cor-
rections on side-stream compres-
sor applicationsmdashany repair
inefficient operation and power
lossesmdashwould be very high Fur-
ther compressors with side-streams
are usually sensitive and difficult
machines to operate In particular
performance curves (performance
pressures efficiency etc) are sen-
sitive to suction inlet conditionsside-stream inlet conditions vol-
ume flow ratio (side-stream vol-
ume to core-flow volume) and side-stream losses
Compressors with side-stream often perform far below
expectations The main reason is that side-stream compres-
sors are different than conventional compressors (without
a side-stream) in design and operation For a compressor
with side-streams tighter tolerances in operating conditions
must be identified and applied Uncontrolled variations of
suction pressure or side-stream pressure are major prob-
lems Another major issue is the variations of the flow ratio
(side-stream flow to core-flow)
Compressor Side-Stream amp Mixing SectionIn many centrifugal compressors the portion of the side-
stream system from the flange connection to the mixing
section is similar to a compressor inlet A great challenge
is ensuring the mixing section provides circumferentially
uniform merged-flow with minimum losses This can be
achieved via effective design of the inlet configuration and
mixing section of the side-stream compressor such that
the impeller can be maintained over the whole operating
range of the compressor In many cases while there are
mixing sections provided for the machine the flows do not
completely mix before entering the impeller of the section-2
(the impeller after the mixing section) Non-uniformity at
inlet flow to the impeller is a key concern for compressor
performance
Another consideration is a compact design of the side-
stream mixing section Specifically a mixing section with
less axial length is always preferred This axial length can af-
fect the compressor rotor dynam-
ics the rotor length and over-
all compressor performance
(design cost operation and
reliability)
The side-stream exit pressure
(side-stream pressure at inlet
of the mixing section) is mainly
a function of the side-stream
flow velocity and the pres-
sure in the previous section of
the compressor Conversely the side-
stream flange pressure can depend on
side-stream flow velocity and section-1
exit conditions Therefore the side-stream
inlet flange volume flow is a function of theflange pressure compressibility (at that
pressure and temperature) and mass flow
Some engineers assume that the side-stream flange pres-
sure is equal to the inlet pressure of the first impeller of the
section-2 This is not true The mixed total pressure can be
estimated on a mass-averaged basis using side-stream total
pressure and return channel exit (section-1) total pressure
In some designs because of the lower static pressure at
the side-stream exit the total pressure at the return channel
exit is lower even though the velocity upstream is roughly
matched for both streams The pressure usually increased
at the returned channel but it can be reduced again at the
side-stream exit While simple in nature this can have an
impact on the prediction of pressure at the side-stream exit
and overall mixing section performance Based on basic flow
principles it was usually assumed that the static pressure
was equal between both flow streams at the mixing location
While this assumption might be used in rough calculations
the accurate simulations have shown this assumption is not
true In fact there are some points (for instance the shroud
wall at the exit of the return channel and the hub wall at
the exit of the side-stream) where this assumption is true
However this is not valid for all locations There are pressure
changes that occur from a side-stream flange to the inlet
of the next section (section-2) which depend on different
factors The first factor is the frictional losses due to side-
stream geometry from side-stream flange to plenum mix-
ing section etc The other factors are pressure changes due
to local curvature and geometry details of mixing section
Another consideration is the operation of a compressor
with side-stream at part-load The performance of the side-
wwwflowcontrolnetworkcom January 2015 25
Figure 1 An example of a centrifugalcompressor with side-stream
COURTESY SIEMENS
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 29456 January 2015
Flow Control Magazine
|
y
g
stream path the mixing section and
the downstream impellers when ma-
chine is operated at part-load or even
off-design operating flows will result
in additional compressor performance
problems In such a case both veloc-
ity profiles and pressure variations in
various parts (side-stream path mixing
section etc) will be different resulting
in complicated flow patterns and com-
plex aerodynamics behaviors
Side-Stream CompressorSectional Performance
Typically vendor-supplied compressor
performance curves reflect flange-to-flange performance because that is
what the plant engineers need to
evaluate the proper operation of their
system (for example from suction to
side-stream and from side-stream to
discharge) In many cases compres-
sor vendors also provide the over-
all compressor performance curves
and performance curves for section-1
(from suction to side-stream) and sec-
tion-2 (from side-stream to discharge)
Flange-to-flange data if not interpret-
ed properly can lead to false conclu-
sions about the relative performance
of individual sections of a compression
system For example if side-stream
losses from the flange to mixing sec-
tion are attributed to the downstream
section (section-2) it will cause the
downstream section (section-2) to
appear low in performance while the
upstream section (section-1) will show
high performance levels
An important behavior to con-
sider is when the actual side-stream
pressure is different than the rated
side-stream pressure When the side-
stream pressure is slightly higher than
the outlet pressure of the section-1
it (section-1) shows a relatively higher
performance compared to the real sec-
tion-1 performance In some cases
the performance of section-1 could be
considerably higher than section-2 In
other words when performance is de-
termined flange to flange the higher
flange pressure is seen as extra ldquopseu-
dordquo work done by the section (since this
is an inconsistent thermodynamic vol-
ume) resulting in a relatively high sec-
tional efficiency (section-1 shows a rel-
atively high efficiency) This is the case
for many compressors with side-stream
because the whole system is designed
(or specifically the side-stream location
is selected) in a way aimed at main-
taining the real side-stream pressure(side-stream inlet) above the section-1
outlet pressure because if the real side-
stream pressure becomes lower than
the section-1 outlet pressure the flow
may (theoretically) reverse
This is particularly important when
the side-stream mass flow is much
lower than the mass flow of core-flow
The above-mentioned reasons explain
why in many simulations calcula-
tions and performance reports related
to compressors with side-stream the
section-1 shows a relatively good ef-
ficiency and section-2 appears low in
efficiency
When the side-stream pressure is
slightly lower than the outlet pressure
of the section-1 the section-1 might
show a relatively lower performance
compared to section-2 This could oc-
cur in some recycle services where the
side-stream is actually a recycle flow
with a mass flow around two to five
times the core-flow The side-stream
(recycle) flow is returned from down-
stream of the compressor to be slightly
compressed and recycled to the down-
stream Such a recycled side-stream
compressor can present unique chal-
lenges for design and operation This
kind of machine usually needs very
special operating procedures and very
fine adjustments regarding operating
pressures and flows
Side-Stream Compressor
Performance amp Operation An important consideration is the sen-
sitivity of compressor overall perfor-
mance curve and sectional perfor-
mance curves to the flow ratio (ratio
of side-stream flow to core-flow) and
to the inlet conditions Variations in
the flow and pressure of the main
suction and side-stream inlet should
be controlled within tight tolerances
For compressors with side-stream the ASME PTC-10 code stipulates limits on
flow ratio (side-stream volume to core-
flow volume) The acceptable variation
in volume flow ratio in a compressor
with a side-stream is +-5 percent as
per ASME PTC code The requested
side-stream pressure tolerance is not
usually specified in compressor codes
but it should be around +- 2 percent
(or sometimes +- 25 percent)
Variance in flow ratio impacts the
velocity levels where the two streams
merge Significant variation in the ve-
locity profile upstream of the impeller
changes the incidence on the blade
leading edge of the following impel-
ler This change in incidence leads to a
change in sectional performance over-
all compressor performance and train
efficiency
If the flow ratio is varied between 95
percent and 105 percent (tolerances
specified in the ASME PTC-10 code)
the flange pressure changes accord-
ingly resulting in a change in the sec-
tional performance and overall perfor-
mance The sectional efficiency varies
sometimes more than +- 4 percent
This variance reduces as the flow is de-
creased toward surge However as the
flow is increased toward overload the
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3045wwwflowcontrolnetworkcom January 2015 27
variance increases up to higher values
(even in some cases three to five times
compared to variations near the surge
zone) For example in a case study
for a compressor with side-streams a
+- 5 percent variation in flow ratio and
associated changes (pressures losses
etc) the sectional efficiency reduced by
approximately 34 percent at the rated
flow at allowable operating points at
the end of curve (near the overload
ie choke) efficiency reduced by ap-
proximately 55 percent These results
show that the variation in sectional
performance and overall performance
due to flow ratio is highest at operat-ing points near the overload and low-
est at operating points near the surge
For compressors which work most of
the time at high flow (flow higher than
rated flow and discharge pressure low-
er than rated pressure) the effects of
flow ratio deviations (and subsequently
efficiency reduction) would be higher
than compressors working on the left-
hand side of curve (say with sufficient
margins near the surge)
In the compressor codes (such as
API 617) the compressor power varia-
tions should be maintained below 4
percent However in some applica-
tions clients require tighter tolerances
on the consumed power sometimes
below 2 percent (or even below 15
percent) Some studies suggest while
+- 5 percent of volume flow ratio is
suitable for performance test as per
ASME PTC-10 code some plants re-
quire tighter control on the consumed
power and compressor performance
(lower limits on the efficiency) the tol-
erances on the volume flow ratio could
be tighter than ASME PTC code In this
regard +- 4 percent tolerance can be
suggested on the volume flow ratio (ra-
tio of side-stream flow to core-flow) of
compressors with side-streams
Based on operational experiences
acceptable variations in volume flow
ratio and inlet pressures (suction inlet
and side-stream inlet) of a compressor
with side-streams are +- 4 percent
and +- 2 percent respectively
Another important consideration is
the required adjustments for the flow
ratio (side-stream flow to core-flow)
Compressors with side-stream usually
require fixed side-stream flange pres-
sures For a compressor with some variations in operation conditions (even
small changes) it is not usually pos-
sible to achieve optimum operation by
keeping the flow ratio (side-stream to
core-flow) constant The flow ratio has
to be adjusted according to the inlet
flow at which the machine is operating
in order to get the required correspond-
ing side-stream flange pressure
Thermal changes have also been
known to cause some instability in
centrifugal compressors An example is
the thermal-induced change of resid-
ual unbalance For compressors with
side-streams which feature tempera-
ture differences between core-flow and
side-stream flow the thermal behav-
ior of the compressor is usually more
complex and requires more attention
Heavy Gas ChallengeHeavy gases (such as heavy hydrocar-
bon gases eg propane propylene
MTBE (Methyl Tertiary Butyl Ether))
have very low gas sonic velocities that
produce high Mach numbers in the
aerodynamic flow paths For these
services because of high Mach num-
ber high flow coefficient stages have
very narrow flow maps characterized
by limited surge and choke margins
Compressors with side-streams in
these services present great challeng-
es This is to say the side-streams and
associated mixing further complicate
design operation and performance
prediction because the pressure tem-
perature and flow conditions at each
one of these side-streams as well
as at the exit of the machine require
stringent tolerances to optimize the
overall efficiency and performance
As such it is important to accuratelymodel design operate and moni-
tor performance characteristics of any
impellers diffusers return channels
and generally all flow-path components
in a compressor with side-stream FC
Amin Almasi
is a senior rotating
machine consultant
in Australia He is
a chartered profes- sional engineer of
Engineers Australia
(MIEAust CPEng ndash
Mechanical) and
IMechE (CEng MIMechE) holds
bachelorrsquos and masterrsquos degrees
in Mechanical Engineering and is
a registered professional engineer
in Queensland He specializes in
rotating machines including cen-
trifugal screw and reciprocating
compressors gas turbines steamturbines engines pumps subsea
offshore rotating machines LNG
units condition monitoring and reli-
ability Mr Almasi is an active mem-
ber of Engineers Australia IMechE
ASME and SPE He can be reached
at aminalmasiymailcom
Amin Almasi
Compressor | Gas Flow | Performance Curve | Side-Stream Flow
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3145
The pressure in the stuffing box
containing the packing can be estimat-
ed by the following equation
SBP = [Discharge ndash Suction] 3 + Suction
Pressure at the bottom of the stuff-
ing box will be higher than the suction
pressure but considerably lower than
the discharge pressure It should be
noted this calculation will yield a con-
servative estimate of stuffing box pres-
sure that can be further reduced by
pump design
A hole in the stuffing box serves as
a port for injecting clean fluid that cir-
culates around a lantern ring aligned
under the flush port The fluid flushes
solids back into the process to protect
the packing from abrasive wear If the
clean fluid is injected at a pressure ex-
ceeding that at the bottom of the stuff-
ing box some of it will leak back into
the process and some will leak out to
the atmosphere Recommended flush
injection pressure is 15ndash30 PSI (1ndash2
Bar) greater than the pressure at the
bottom of the stuffing box
Fluid injection is also used to lubri-
cate and cool dry-running packing that
is subject to frictional heat and to pre-
vent air from entering the pump which
reduces flow and operating efficiency
Centrifugal pumps utilize three
types of impellersmdashopen semi-open
and closed (Figures 2 3 amp 4) Open
designs prevent fluids with large solids
from clogging the impellers but at theexpense of pump efficiency Backing
plates on semi-open designs serve to
trap the fluid for more efficient opera-
tion Closed impellers are for use with
clean fluids since solids could ac-
cumulate in the eye which would re-
quire tearing down the pump to remove
them
Single-Stage CentrifugalPumpsSingle-stage centrifugal pumps typi-
cally have good bearing support of the
shaft with few run-out or ldquowhiprdquo prob-
lems However in some cases they
are subject to cavitation This occurs
in the eye of the impeller where the
fluid is under vacuum If the pressure
is low enough it will cause the material
to vaporize forming air or water vapor
bubbles As the fluid passes through
How Pumping Systems Design Affects Sealing Performance
By Chris Boss
8 January 2015
Flow Control Magazine
|
Understanding how different types of pump designs impact
sealing is critical to optimizing efficiency safety and lon-
gevity of the sealing system Used for a wide variety of media
including clear fluids solutions and slurries single-stage
centrifugal pumps are one of the most common
types (Figure 1) Fluid drawn into these pumps
enters the eye of an impeller that spins itto the outside of its container
or volute building pressure as
it moves toward discharge
Some of this fluid will work
its way behind the impeller
where it must be sealed with
compression packing or a
mechanical seal
Figure 1
Figure 2 Figure 3 Figure 4
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3245
the pump under increasing pressure
these bubbles implode sending shock
and vibration through the impeller
adversely affecting the seal This phe-
nomenon can be mitigated by running
the pump at slower speed and higher
pressure at the suction end to prevent
air from entering the fluid
Double-Ended Split-CasePumpsOperating on the same centrifugal prin-
ciple but slightly different geometry are
double-ended split-case pumps (Figure
5) Fluid enters both ends of the pump
and is directed into the eye of an impel-ler which spins it out of the volute to
discharge Packing is installed on both
the shaft and bearing ends so the stuff-
ing box is exposed only to suction pres-
sure which is usually quite low
Axial Flow Pumps Axial flow pumps operate like hydro
turbines in reverse whereby a propeller
(or axial impeller) pushes the fluid to
discharge (Figure 6)
Since the stuffing box is located
downstream of the propeller at the dis-
charge end of the pump the packing is
exposed to the full discharge pressure
Vertical PumpsVertical turbine pumps are typically
flange-mounted on a floor extending
downward into a water-filled sump
hole (Figure 7) Available as single- or
multi-stage pumps they feature an
impeller or series of impellers rotated
simultaneously by a single shaft The
impellers increase the pressure of the
upward flow subjecting the stuffing box
to full discharge pressure
Vertical pumps can be quite long so
inadequate bearing support can cause
the shaft to run out This can induce
undesirable lateral motion on the pack-
ing Worse the packing may be forced
to serve both as a bearing and a seal To
withstand these conditions the packing
should be resilient elastic and resistant
to deformation These properties rule
out packing such as graphite foil in favor
of fiber-based materials
Multi-Stage PumpsMulti-stage pumps are used for high-
pressure applications such as feeding
the boilers in steam-powered generating
plants Stuffing box pressure can vary
with pump design and number of stag-
es Designed for clean fluids and high
operating speeds these pumps typically
have high- and low-pressure ends with ahydraulic pressure equalization line run-
ning between the stuffing boxes
Like vertical pumps multi-stage
pumps feature a series of impellers to
build fluid discharge pressure In the
case of the six-stage pump pictured in
Figure 8 fluid enters at the drive end
where a stuffing box is exposed to suc-
tion pressure Channeled from one
impeller to the next through the pump
casting the fluid can reach extremely
high pressures at discharge
A second stuffing box located at the
bearing end is exposed to an intermedi-
ate pressure from the third impeller This
pressure is greater than the suction pres-
sure but much less than the discharge
pressure which can reach 2000 PSI
Fortunately the stuffing boxes in
these pumps are not exposed to dis-
charge pressures and typically see be-
low 500 PSI which is within the range
of some packing materials
wwwflowcontrolnetworkcom January 2015 29
Figure 5
Figure 6
Figure 7
Figure 8
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 33450 January 2015
Flow Control Magazine
| Gear PumpsPositive-displacement or gear pumps
operate on a different principle than
centrifugal pumps In external gear
pumps the fluid flows around the out-
side of the gears the intermeshing
of which forces it through the pump
to discharge (Figure 9) This design
makes these pumps particularly suit-
able for use with highly viscous fluids
such as resins emulsions syrups and
adhesives As such they are used for
transfer or metering applications
It should be noted gear pumps will
continue to displace fluid as long as
their shafts are turning which can pose
a problem if a clog occurs at the dis-
charge The resulting buildup of pres-
sure can blow out seals and damage
the pump Therefore most gear pumps
have pressure relief valves to divert
fluid back to the suction side for re-
circulation through the pump Internal
gear pumps operate slightly differently
but also have pressure relief valves to
prevent damage from excessive pres-
sure (Figure 10) In both external and
internal gear pumps the maximum
stuffing box pressure is determined by
these valves
Other rotating equipment includes
mixersagitators which are similar to
pumps in terms of the speeds to which
the packing is exposed There are ba-
sically three types of mixersagitators
top- bottom- and side-entry Top-entry
models are subject to the same con-
cerns about shaft run-out ldquowhiprdquo and
lateral forces on the paddles that are
encountered in some vertical pumps
Although some fluid may splash onto
the packing these mixers basically run
dry so the packing must have the abil-
ity to dissipate the resulting frictional
heat
In bottom-entry mixers the packing
is always exposed to fluid and may also
be exposed to solids requiring abra-
sion-resistance If the seal fails the en-
tire contents of the tank will eventually
drain out onto the bearings the floor
and other components under the stuff-
ing box
The packing in side-entry mixers may
be fully or intermittently exposed to flu-
id as well as side loading and vibration
Aside from media temperature
speed and other application variables
the configurations and operating prin-
ciples of rotary-type pumps exert differ-
ent forces on the seals used to keep
them from leaking These forces can
spell the difference between accept-
able seal performance and failure
Understanding these differences has
important implications that should be
taken into account to assure proper
sealing selection for long-term trou-
ble-free performance FC
wwwgarlockcom
Chris Boss is
a senior applica-
tions engineer for
Garlock Sealing
Technologies in
Palmyra NY He
has held various
positions in produc-
tion engineering
product development and applica-
tions engineering for the companyrsquos
compression packing division He
is a BSME graduate of the State
University of New York at Buffalo Mr
Boss can be reached at 800 448-
6688 or chrisbossgarlockcom
Chris Boss
Cavitation | Centrifugal Pump | Pump Packing | Sealing System
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Figure 9
Figure 10
Aside from media temperature speed and
other application variables the configurations
and operating principles of rotary-type
pumps exert different forces on the seals used
to keep them from leaking These forces can
spell the difference between acceptable seal
performance and failure
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3445
NS IDERNDUSTRIAL AUTOMATION + PROCESS CONTROL
WANT
INFORMATION
ON THE
automationindustry
SUBSCRIBE NOW at wwwiainsidercouk
Published by Spitzer and Boyes LLC Write in 15 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
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Frost says the push from developing
economies is important as the market
is technologically mature and seeing
restricted growth in developed econo-
mies This is particularly true in Europe
and North America where recent finan-
cial insta-
bility has
reduced capital expenditure across end-
user industries
Bill Moore senior vice president of
sales development and channel man-
agement for global bearings manufac-
turer SKF says ldquosmartrdquo products and
the expansion of robust reliability pro-
grams are helping to drive new invest-
ment particularly in developed coun-
tries where the cost to compete is
high Frost says the magnitude of
the existing global installed base will
strengthen the need for replacement
and upgrades adding to market de-
mand as well
Frost says despite the potential
in developing economies the focus
on price as a product differentiator
may lead to intense price pressures
among manufacturers and bring down
the value of the overall market in the
short term The growing trend among
consumers to choose low-cost Chinese
imports will complicate this challenge
As price and quality become stan-
dardized across the globe customers
will base more of their purchasing deci-
sions on value-added services accord-
ing to Frost This will push manufactur-
ers to create more maintenance-free
solutions such as lubrication-free
bearings that offer end-users savings
on service and replacement costs and
reduce downtimeldquoOffering a complete line of prod-
ucts with comprehensive services will
be another feather in the cap of ven-
dors looking to widen their consumer
baserdquo notes Frost Industrial Automa-
tion and Process Control Research
Analyst Guru Mahesh
Moore says the trend of outsourcing
manufacturing to regions where labor
and production costs are favorable is
becoming less of a factor
ldquoThe days when cheap labor made
a significant difference in where a prod-
uct is manufactured mdash particularly high
value-added products or high weight
and bulk products mdash are coming to
an end as the cost of transportation
storage and inventory balance out the
benefits of production costs where la-
bor is a smaller percentage of the cost
of manufacturingrdquo Moore says ldquoLocal
manufacturing development will indeed
come to developing countries as their
ability to create markets that generate
economies of scale that support local
production is a clear trend and one that
all manufacturers will pay attention tordquo
Moore says that development of
maintenance-free or predictive tech-
nologies and products will be a sig-
nificant advantage to everyone in the
Bearing amp Coupling Manufacturers Focus
onDEVELOPING Economies
amp EFFICIENCY InnovationBy Amy W Richardson
2 January 2015
Flow Control Magazine
|
gy
Anew study from Frost amp Sullivan (wwwfrostcom) fore-
casts steady growth for the overall bearings and couplings
market based on rapid industrial development in high-growth
regions Specifically Frost predicts development in Mexico
Indonesia Nigeria Turkey Brazil Russia India and Chinawill help boost the bearings amp couplings market from $2206
billion in 2013 to an estimated $2676 billion in 2018
The development of maintenance-freeor predictive technologies will helpboost growth in the bearings market For example SKF is developing products that will automatically notifyusers when a bearing or mechanicalrotating component is approachingthe end of its useful life Pictured hereis an SKF Microlog analyzer a por- table condition monitoring tool
COURTESY SKF
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
improved productivity through simplified solutions The powerful technology and tools ensure repeatable
reliable accurate measurements Easier access to process data allows for better troubleshooting process
optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
For daily product notes visit the lsquoFeatured Productsrsquo section flowcontrolnetworkcom
ON THE WEB
1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3845
FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
and benefits as well as grids of
instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
services provided for the
mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
Brought to you by Beamex
Your Source For Fluid Handling Videos
Go towwwflowcontrolnetworkcomfreeinfo
Select appropriate issue ofFlow Control Magazine
Select advertisements thatinterest you
Enter your email amp clickldquoSubmit Requestrdquo
1
2
3
4
PRODUCT
INFORMATION
ONLINE
Follow these 4 steps to receive freeproduct information from suppliers
FREE
FEATURED VIDEO How to Calibrate aPressure Measurement Loop
For more information about FlowTube
sponsor packs email FlowControlGrandViewMediacom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4245
THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
Name ________________________________________________________________
Title _________________________________________________________________
Company _____________________________________________________________
AddressCityStateZip __________________________________________________
______________________________________________________________________
Phone ________________________________________________________________
E-Mail ________________________________________________________________
One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545
![Page 14: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/14.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1445
New Technique Could ReduceEnergy Required for Oil Refinement
UK scientists have developed a
technique they say has the poten-
tial to dramatically reduce the amount
of energy required for the refinement
of crude oil
Professor Martin Schroumlder and Dr
Sihai Yang from The University of Not-
tingham (wwwnottinghamacuk ) have
led a multi-disciplinary team of scien-
tists from Nottingham the Science and
Technology Facilities Councilrsquos (STFC)
ISIS Neutron Facility Oak Ridge Na-tional Laboratory and Diamond Light
Source to discover a porous material
that works like a chemical sponge to
separate a number of important gases
from mixtures generated during crude
oil refinement
According to a news release from
The University of Nottingham the ex-
isting industrial process uses ldquohuge
amounts of energy to separate and pu-
rify these gases so the new technique
has the potential to revolutionize the oil
industry by significantly reducing car-
bon emissions and making the process
more environmentally friendlyrdquo
Commercially UsefulCrude oil is a raw material that is
refined to produce fuel for cars toheat homes and to create polymers
and other useful materials It is made
up of a complex mixture of hydro-
carbons (chemical compounds that
contain only hydrogen and carbon) of
which certain components are espe-
cially commercially useful
One industrial process used to
achieve hydrocarbon separation is
called ldquocryogenic distillationrdquo which is
widely used worldwide and uses vast
amounts of energy to generate the high
pressures and cryogenic temperatures
required to ensure efficient separation
research amp development
wwwflowcontrolnetworkcom January 2015 | 11
PLASTIC CONTROL VALVES FORALL YOUR CORROSIVE APPLICATIONS
PO Box 938 bull Angleton TX 77516Tel (979) 849-8266 bull wwwcollinsinstcom
Collins plastic control valves are
highly responsive control valves
designed for use with corrosive
media andor corrosive atmos-
pheres
Collins valves feature all-plastic
construction with bodies in PVDF
PP PVC and Halar in various body
styles from 12 - 2 with Globe
Angle or Corner configurations and
many trim sizes and materials
Valves may be furnished without
positioner for ON-OFF applications
Call for more information on our
plastic control valves
Write in 9 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1545
of hydrocarbon mixtures into pure components
However researchers say an innovative solution may
have come in the form of a novel chemical sponge This
porous material a metal-organic framework was devel-
oped by the same team at Nottingham just two years ago
Now in research published in Nature Chemistry for the
first time scientists have proven that it can be used toseparate hydrocarbon mixtures without the need for high
process pressures or very low process temperatures
Reusable MaterialsMade from cheap organic materials aluminum nitrate
salt and water the porous material called NOTT-300 is
able to adsorb different gases found in mixtures of hydro-
carbons at different rates making it possible to sepa-
rate them and extract the most useful ones NOTT-300
requires less energy to function than existing methods
as it operates at ambient temperatures and normal pres-
sures researchers say The gases that are adsorbed intoNOTT-300 can be removed without a significant energy
input and therefore the material can be easily reused
The team of scientists from Nottingham used Diamond
the UKrsquos synchrotron science facility as well as STFCrsquos
ISIS Neutron Facility and Oak Ridge National Laboratory
the UKrsquos and USArsquos world-leading neutron facilities re-
spectively to prove that the sponge works under real-life
conditions
Professor Martin Schroumlder Dean of the Faculty of Sci-
ence at Nottingham said in the news release ldquoIt is a very
important to be able to separate different hydrocarbons ef-
fectively and efficiently with low-energy consumption Po-rous solids such as the metal-organic framework system
studied here represent important materials for the future
development of low-energy separation technologies We
are most grateful to our collaborators at ISIS Neutron Fa-
cility Oak Ridge National Laboratory and Diamond Light
Source in bringing this work to fruitionrdquo
Significant Impact on Oil IndustryDr Sihai Yang the winner of Diamond Young Scientist
and BTM Willis Prize is a Senior Research Fellow at
Nottingham He led the project together with Professor
Martin Schroumlder Yang said ldquoWith the help of advancedcentral facilities like Diamond ISIS and ORNL we have
developed a new separation technique which can poten-
tially reduce the energy usage associated with oil petro-
leum and chemical industries which require the separa-
tion of raw hydrocarbons from crude oil
The discovery of the new material NOTT-300 could
have a significant impact on the oil industry by removing
the necessity for some energy-intensive refinement pro-
cesses researchers say
The research was funded by Engineering and Physical
Sciences Research Council (EPSRC) the European Re-
search Council (ERC) The University of Nottingham andLeverhulme Trust
12 | January 2015
Flow Control Magazine
Write in 21 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
No media contact - No risk of leaks
No process Shut-Downs for installation
No bypass needed
For hazardous area locations (FM approved)
Monitor your Total Acid Consumption
Increase your Plant Up-Time
Balance your Processes
PIOXreg S
PIOXreg S - the evolution of flow and concen-
tration measurement in acid production
Non-intrusive mass flow concen-
tration and density measurement
of aggressive media
wwwpiox-scom
wwwfleximcom
Contact us for a free trial measurement
Thank you for your votes and
making PIOXreg S a Flow Control
Awards Winner
THE OUTLOOK | News amp Notes
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1645
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 174514 | January 2015 Flow Control Magazine
PPLICATIONS CORNER | Process Instrumentation
This is the final article in a series based on the troubleshoot-
ing of a mysterious unit shutdown due to flowmeter perfor-
mance problems
If yoursquove followed this column for most of 2014 you know
that what should have been a liquid ammonia stream to the
feed plant became problematic due to the occurrence of
bubbles of ammonia gas These bubbles caused an ultrasonic
flowmeter in a unit to indicate zero flow and caused the reactor
to scram (shut down) under warm operating conditions The source of the bubbles was traced back to the pres-
sure drop associated with a control valve located at the
exit of the liquid ammonia tank farm
This issue was resolved by identifying the problem
and fixing it at its source This was a pragmatic ap-
proach at the time (early 1980s) given the operation
of the cooling system in the unit and the limited selec-
tion of applicable flowmeter technologies
By the early 1990s changes were implemented that elim-
inated all process cooling requirementsmdashexcept for the small
jacketed cooler upstream of the liquid ammonia flowmeter In
other words after these changes the entire cooling system
would be operated and maintained to cool a few meters of
one small ammonia pipe Coincidently at about the same
time Coriolis mass flowmeters became more mature and
could reasonably measure the mass flow of liquid streams
with homogeneous low levels of vapor
The convergence of these two events resulted in another
approach to the problem that was not available in the early
1980smdashie install a Coriolis flowmeter that could operate in
the presence of bubbles The purchase and installation of a
Coriolis mass flowmeter was given high priority given its im-pact on unit operation economics and safety (by eliminating
the ldquomidget-makerrdquo (see March 2014 page 14))
Plant requirements and the technology that can meet
plant needs keep changing An excellent solution today can
become outdated in just a few years However there are few
substitutes for understanding fundamentals when addressing
a problem In other words there can be more than one way
to skin a cat FC
wwwspitzerandboyescom
Problem Solved AgainA Coriolis mass flowmeter provides a better solution
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anti-siphon applications
Write in 10 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
David W Spitzer
Ammonia Gas | Coriolis Flowmeter | David W Spitzer | Scram | Troubleshooting
FLOWSTREAM Find related content flowcontrolnetworkcom
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and Boyes
LLC offering engineering seminars strategic marketingconsulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer can be reached at 845 623-
1830 or at wwwspitzerandboyescom
The purchase and installation of a
Coriolis mass flowmeter was given
high priority given its impact on unit
operation economics and safetyldquordquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1845
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Beyond Control The NEW Research Controlreg SRD positioner does
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1945
Process improvements to increase yield or cut manufactur-
ing costs typically require enhanced process control but the
installed base of measurement instrumentation in a process
plant may simply be unable to facilitate improvements because
of age inadequate performance or unreliability Maintenance
cost and unscheduled process downtime for an aging process
plant can be very damaging to the balance sheet Upgrading
to new more accurate and more reliable instrumentation can
be prohibitively expensive New plant construction must alsomaintain a focus on optimizing costs for the process control
infrastructure The budget approval decision for new plant
construction must weigh such costs against projected market
conditions for the products that the plant is intended to manu-facture In todayrsquos volatile global marketplace return on invest-
ment calculations for plant upgrade or new plant construction
projects may go through several iterations before the trigger is
finally pulled or indeed not pulled
This article describes advances in two-wire instrumenta-
tion specifically in relation to flowmeters that have taken
place in the past few years and the significant cost benefits
that this new technology can realize for plant builders and op-
erators in terms of capital investment and cost of ownership
The Significance of Two-Wire Loop Power
A survey involving 204 participants in the chemical indus-try across Germany Switzerland the UK Canada and the
United States (Manfred Koenig PhD KIM Ludwigshafen
Germany 2006) revealed an 87 percent preference for two-
wire instrumentation versus four-wire in process applications
and 89 percent for utilities This overwhelming preference
may stem from the fact that older process plants were built
with two-wire twisted-pair cable networks connecting all
process units and measuring instruments together in an
overall plant control scheme
However these existing cables are relatively unsophisti-
cated and incapable of supporting anything but low-energy
instrumentation that is insensitive to interference from otherelectrical sources that might be sharing the same cable con-
duit Further the low energy levels supported by these two-
wire loops are more easily rendered safe in terms of explo-
sive risk in hazardous areas containing flammable materials
Many older process plants are also likely to have a significant
installed base of flowmeters employing pre-war (pre-1945)
technology such as positive displacement (PD) turbine vari-
able area (VA or Rotameter) and differential pressure (dP)
Market data firm Flow Research Inc (wwwflowresearch
com) indicates collectively a future compound negative annual
growth rate approaching minus 3 percent to 5 percent for PD
turbine and VA flowmeter types while dP is expected to keeppace with market growth (World Market for Flowmeters 2010)
YSTEMS DESIGN | Flow Measurement
16 | January 2015
Flow Control Magazine
The Two-Wire
ADVANTAGENew wiring options enable modern instrumentsto drive cost savings in existing plant systems
By Steve Milford
Advances in two-wire instrumentation have enabled mod- ern technology to be employed to the advantage of older
plant and process systems
Some chemical manufacturing plants are
competing for survival not only externally
against other global companies but also
internally among the global facilities of theirown company Other industry sectors face
similar challenges
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2045wwwflowcontrolnetworkcom January 2015 | 17
The Need to Replace Older TechnologiesUntil the 21st century two-wire loops were only able
to support these relatively unsophisticated instruments
which convert their measurement by various means into a
4-20mA output or pulse signal to the control system The
more advanced post-war flowmeter technologies such as
Coriolis ultrasonic or electromagnetic flowmeters have
until just eight years ago required a dedicated power sup-
ply for their function in addition to the output loop and
thus a four-wire infrastructure was required as a minimum
Therefore upgrading older two-wire meter devices to moremodern four-wire technology could require significant
expenditure in terms of the installation of separate power
cables and supply modules
There was a major breakthrough in 2006 when a true
two-wire loop-powered inline liquid ultrasonic flowmeter
was introduced (Figure 1) The nature of this breakthrough
was innovation in device power management This was the
missing piece up to that point because to be a true loop-
powered device the meter had to directly provide a full 16
mA span using less than 36 mA of remaining loop current
and less than 1 Watt of electrical energy The flowmeter
operated on a single 4-20 mA HART two-wire loop wasremotely powered by a DC supply was certified Class 1 Divi-
sion 1 and could be deployed as Intrinsically Safe through
the use of an approved safety barrier
A true two-wire loop-powered Coriolis flowmeter followed
in 2011 (Figure 2) employing a new and more advanced
common electronics platform A two-wire loop-powered inline
ultrasonic flowmeter for low-pressure gas was introduced in
2012 and a second two-wire loop-powered Coriolis meter fol-
lowed in 2013 offering improved measurement performance
and an additional high-performance meter tube material
Electromagnetic and vortex flowmeters had already been
available for some years in two-wire loop-powered form butimproved performance resulted as these designs were incor-
COURTESYENDRESS+HAUSER
Figure 1 A two-wire ultrasonic flow- meter released in 2006 operated ona single 4-20 mA two-wire loop
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I I I I LL I
I I I I LL I
copy COPYRIGHT 2015 OMEGA ENGINEERING INC ALL RIGHTS RESERVED
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Prices listed are those in effect at the time of publication and are subject to change without noticePlease contact OMEGArsquos sales department for current prices
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FPD3300 SeriesStarts at
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Positive Displacement Flow Meterfor Fuels and Oils
bull Aluminum Bodybull FKM Sealsbull Temperatures up to
80ordmC (176ordmF)bull NPT or BSP Threadsbull DIN JIS or ANSI
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Thermal Imaging CameraFor Inspection andFactory Diagnosis
Note Not for ExportUSA Only
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 214518 | January 2015
Flow Control Magazine
porated into their new common electron-
ics platform in 2013 So all the ldquomodernrdquo
flow measurement technologies mdash that
is to say those introduced post-war mdash
have become available as two-wire loop-
powered devices with one exception
namely thermal mass (thermal disper-
sion) meters Unfortunately the power
requirements for this technology exceed
what is currently deemed possible withtwo-wire loop-power management
Payback forTechnology UpgradeConsider a 1rdquo process line
containing a liquid process
ingredient costing $1lb at a
mass flowrate of 150 lbmin-
ute We have $150minute
flowing in the line translating
to $9000hour and $72000
per eight-hour shift That cal-culates further to $360000
per five-day working week and
for a working year of 40 weeks for
example that is $144 million Assume
the existing device is a turbine flowmeter
Now imagine a two-wire loop-
powered Coriolis mass flowmeter is
installed in place of the existing meter
The line would need to be drained and
probably one process flange replaced
allowing the Coriolis to fit mechanically
in place of the turbine However thetwo-wire loop already used for carrying
the existing meterrsquos flow signal to the
control room can be used unaltered
for the complete electrical installation
aspects of the Coriolis flowmeter
The upside of the change is signifi-
cant and clear cut Assuming the exist-
ing meter measurement uncertainty was02 percent of reading then measure-
ment uncertainty improves through use
of Coriolis to 01 percent of reading
giving a 01100 x $14400000 im-
provement in control of the ingredient
annually or $14400 A two-wire Coriolis
mass flowmeter with 01 percent mass
flow accuracy would be paid for in ap-
proximately 6-8 months In practice the
improvement in measurement uncer-
tainty would be greater as the operator
would gain temperature and density in-formation from the Coriolis and the mea-
surement would be devoid of any fluid
property dependence Viscosity change
for example can have a major impact on
turbine meter performance Mechanical
wear and tear that turbine meters even-
tually experience which causes them to
under-register flow is precluded by mod-
ern devices like Coriolis
Furthermore if the process ingredient
was being blended with another then ad-
ditional process improvements could berealized through in-line blending control
using Coriolis technology for final density
as the control point It is possible to have
dual 4-20 mA outputs from two-wire
loop-powered meters but as the main
4-20 mA output representing the prima-
ry variable is also HART then an external
HART Loop Converter or HART IO card in
the control system can provide second-
ary tertiary and quaternary variables as
4-20 mA signals A Coriolis meter is trulya multi-variable device Certain two-wire
devices are also available with Profibus
or Foundation Fieldbus communication
Cutting Wiring CostsIn 2003 WIBEXERA (International
Instrument Usersrsquo Associations) Report
T 2732 X 03 was published and it pro- vided an average survey of prices quoted
in projects at that time for the provision
of power supplies for four-wire instru-
ments The price ranged from euro1200
to euro1800 per instrument depending
upon design and plant characteristics
for an average cost of euro1500 (about
$2000) It would be reasonable to
assume an inflationary factor of 2 per-
cent per annum giving an approximate
current-day figure of $2500
From another source within thechemical industry an estimation of
$40foot to $50foot was given for in-
stallation of four-wire cabling For a
linear 50-foot cable run with for ex-
ample a 10-foot vertical at each end
this equates to $3150 Actual costs
and budget estimates have been given
as high as $10000
The Extent of the Opportunity The modern post-war flow measure-
ment technologies have different powerrequirements and consequently they
are not all available for the
same size range in two-wire
loop-power form For example
two-wire Coriolis flowmeters
are limited to 2rdquo diameter
electromagnetic and inline
low-pressure gas ultrasonics
are limited to 8rdquo and vortex
and inline liquid ultrasonic are
limited to 12rdquo
Nevertheless for thechemical industry in particu-
lar perhaps two-thirds of the
process pipes in a plant will be no larger
than 2rdquo and even when the host process
pipe is larger a correctly sized flowmeter
can still be less than 2rdquo There is consid-
erable scope for two-wire loop-power to
deliver value for flow measurement ap-
plications with total safety
The virtues of Coriolis technology
have been covered but what about
other two-wire technologies An elec-tromagnetic flowmeter in two-wire form
YSTEMS DESIGN | Flow Measurement
In todayrsquos volatile global mar-
ketplace return on investment
calculations for plant upgrade or
new plant construction projects
may go through several itera-
tions before the trigger is finally
pulled or indeed not pulled
ldquo
rdquo
COURTESYENDRESS+HAUSER
Figure 2 Two-wire Coriolis flowme- ters became available in 2011
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2245
can be used on water wastewater or
a light water-based slurry provided the
fluid has around a 20 microSeimenscenti-
metre (microScm) electrical conductivity
A magnetic flowmeter is full bore un-
less flowrates dictate a reduced meter
size in the interests of performance and
so there are no intrusions into the flow
stream and no pressure loss An accu-
racy of 05 percent of reading is normal
from a two-wire magnetic meter and a
modest five diameters (5D) of straight in-let run is needed to avoid error from up-
stream flow disturbances When the fluid
exhibits insufficient conductivity then
the same performance and installation
requirements can be met by an inline ul-
trasonic flowmeter provided the liquid is
essentially clean and bubble-free
For gas or steam applications a vor-
tex meter is the normal choice Using a
built-in temperature sensor a two-wire
loop-powered vortex meter can calculate
mass flow of saturated steam using in-ternal steam tables An external pressure
input allows mass flow of steam to be ac-
curately calculated even when saturated
steam becomes superheated as can oc-
cur downstream of a pressure regulating
valve With mass flow known the vortex
meter can calculate energy and heat flow
A new and exciting development is
the ability of the vortex meter to indicate
wet steam and calculate dryness frac-
tion or steam quality For safety and ef-
ficiency saturated steam should be dry
and free from condensate that is to say
it should possess a high steam quality
factor However the dry or wet state of
saturated steam can sit on a knife-edge
and shift to the opposing state due to
the slightest change in process condi-
tions Rapid and reliable indication of
this change of state is now available
Perhaps the most astonishingachievement in the power management
of two-wire loop-power flowmeters is
that of the ultrasonic biogas meter It is
now possible not only to measure the
flow of wet dirty variable composition
and low-pressure anaerobic digester
gas landfill gas and coal bed methane
gas with a two-wire loop-powered ultra-
sonic flowmeter but also the same de-
vice uses an inbuilt temperature sensor
in combination with measured sound
velocity to calculate methane contentcalorific value and energy flow
Technology to Take UsForwardModern flow technologies provide instru-
ment engineers with vital self-monitoring
information The format of such infor-
mation is easier to understand and act
upon when presented in accordance
with harmonized international guidelines
for online plant asset management eg
NAMUR Standard 107
Continuous plain-text self-diagnostic
and process-related information with
suggested remedies (Figure 3) make it
possible for instrument engineers andoperators to take action at the appro-
priate time mdash immediately or during
the next scheduled shutdown mdash saving
time and money by knowing the exact
health of their measuring point and the
probable actions required to rectify any
abnormal conditions Device verifica-
tion offering third-party validated trace-
ability can be performed on demand ei-
ther locally or remotely from the control
room without the expense of a man in
the field Calibration is then avoided ordeferred without process interruption
Where a process plant has a large
installed base of older mechanical tech-
nologies the decision to embark upon a
program of replacement for plant mod-
ernization cannot of course be taken
easily There are the stocks of spare
parts to consider along with the plant
instrument technicians who are trained
on and at ease with the old devices
However a process plant that retains
the older technology going forward willbe at risk and may find it increasingly
difficult or even impossible to maintain
a cost position that competes effective-
ly in the global market FC
wwwusendresscom
wwwflowcontrolnetworkcom January 2015 | 19
Steve Milford
is a Flow Product
Business Manager
for Endress+Hauser
Inc in Greenwood
Ind He has been
involved in flow
measurement since
1983 and has been
actively involved with standards devel-
opment for flow technology within the
International Standards Organization
(ISO) and the British Standards
Institute Mr Milford can be reached
at stevemilfordusendresscom
Steve Milford
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Coriolis Flowmeter | Magnetic Flowmeter | Two-Wire | Ultrasonic Flowmeter | Vortex Flowmeter
Figure 3 A modern instrumentrsquos display module can provide continuous plain- text self-diagnostic and process-related information
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2345
The bottom line is the volume of gas under one set of
pressure and temperature conditions is not the same as it
would be for the gas under different conditions Why is thisimportant Without compensation for compressibility read-
ings taken by gas flowmeters can result in measurementsmdash
and costs to the buyermdashsignificantly lower or higher than they
should be
The flow of gas in a system can be accounted for and
reported in a number of ways such as by volume by mass
flowrate and by energy Inline turbine meters can offer both
reliability and accuracy in measuring gas flow when matched
with a monitor capable of calculating and displaying results
that have been adjusted for the nature of the gas and impor-
tantly the pressure and temperature
Measuring Flow with an Inline TurbineFlowmeter
With an inline turbine meter gas flows into the meter through
a length of piping that helps to pre-condition the flow by
reducing undesirable swirls and asymmetry Where consid-
ered necessary a flow straightener may even be installed in
line to create a uniform flow profile to the extent possible
As can be seen in Figure 1 a rotor support within the tur-
bine housing further conditions the flow and directs it through
the blades of the rotor High-precision ball bearings allow the
rotor to freely rotate on the shaft
The rotorrsquos rotational speed is directly proportional to the velocity of the fluid passing through the meter The rotor itself
incorporates magnets (or magnetic blades depending on thedesign) while the housing is non-magnetic
A proximity sensor (also known as a pickup coil) is located
in line with the rotor and detects the electrical pulses gener-
ated by the ferrous rotor spinning through the magnetic field
Each pulse represents a discrete volume of gas The out-
put frequency provides the indication of the gas flow rate and
the accumulated pulses over a specified time represent the
total volume of fluid for that measurement period
Need for Calibration The flowrate of the gas through the meter cannot be deter-
mined accurately unless the meter is calibrated The fac-tory calibration determines the meterrsquos constant known
as a K-factor which is then inputted into the gas monitor
PPLICATION NOTES | Flow Measurement
20 | January 2015
Flow Control Magazine
COMPENSATING for
Compressibility inMeasuring Gas Flow Why K-factor adjustment is essential foraccurate inline turbine flow measurement
Unlike crude oil and other liquid fossilfuels natural gas poses a challenge
in monitoring the quantity of gas flowing
through pipelines While liquids do not com-
press gases do and the mass flowrate of
gas being transmitted through gathering
lines depends on both the pressure and
temperature
By Kevin Clark
Figure 1 Internal components of a liquid turbine flowmeter
C O U R T E S Y
T U R B I N E S
I N C
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2445
Wondering Whether the
Pump Guy Seminar
Is for YouCheck out the ldquoPump Guy Insightsrdquo
video series flwctrlcompginsights
PUMP GUY INSIGHT 1NPSHa vs NPSHrmdashWhy all pumps need gauges
PUMP GUY INSIGHT 3How to Operate Your Pump at Best Efficiency
PUMP GUY INSIGHT 5Head vs Flow
PUMP GUY INSIGHT 2 Your Pumps Are Constantly Moving On Their Curves
PUMP GUY INSIGHT 4 The Role of the Pump Reliability Chain
PUMP GUY INSIGHT 6How to Read a Pump Curve
PARTNER SPONSORSFor more information and to register
for upcoming Pump Guy Seminars
visit FlowControlNetworkcomPumpGuy
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2545
PPLICATION NOTES | Flow Measurement
22 | January 2015
Flow Control Magazine
Gas flowmeters measure the actual volume of gas passing
through the meter per minute irrespective of pressure and
temperature1
The volumetric flowrate of a gas is often corrected to
ldquostandardizedrdquo conditions of pressure and temperature While
ldquostandardrdquo conditions can vary depending on the definition
in the US this typically means a pressure of 1473 PSIA(pounds per square inch absolute) and a temperature of 60 F
The flowrate measurement is reported in standard cubic feet
per minute (SCFM)
Compensating for changes in pressure and temperature is
critical Consider a meter system setup for flowing conditions
of 60 PSIG (pounds per square inch gauge) and 60 F and the
line pressure decreases to 50 PSIG while the temperature
remains constant The difference in SCFM between the two
is more than 15 percent which would cost the buyer more
for the gas than it should As Table 1 demonstrates even a
small variation in pressure will result in a surprisingly high er-
ror percentage
Automation of the K-Factor The K-factor is established by an initial factory calibration In
the case of a non-compensated flow monitor any variations
in pressure and temperature will result in manual adjust-
ments needed to the K-factor In order to maintain accurate
flow measurement users must monitor pressure and temper-
ature and make corresponding adjustments to the K-factor To eliminate these manual adjustments some suppliers offer
a flow monitor that automatically adjusts for any changes in
pressure and temperature
These monitors provide accurate flow measurement regard-
less of changing environmental conditions in some cases sup-
porting applications with pressures as high as 15000 PSIG and
temperatures between -350 F to 350 F with a standard accura-
cy of +-1 percent over a flow range of 05 ACFM to 650 ACFM
Final NotesDuring the operation of a flowmeter system the ability to obtain
a readout mdash and to adjust for line pressure and temperaturechanges mdash is sometimes compromised by a lack of electric
power This issue is especially true along gas pipelines in remote
areas To overcome this limitation some manufacturers have
designed low-powered flow monitors which can operate for up
to on year on a single lithium D-cell battery
It is important for users to recognize the effects of the
compressibility of gas As such the quantity of a gas flow-
ing through a gas flowmeter depends on the pressure and
temperature In order to ensure accuracy any flowmetering
system must employ a means to correct for these effects
Otherwise the readout is certain to be in error and could be
unnecessarily costing money This is particularly crucial onwellhead production and in billing scenarios FC
wwwturbinesincorporatedcom
Notations1 The measurement factor in the US is known as the
ACFM actual cubic feet per minute (Metric units are typically
ACMH actual cubic meters per hour)
Table 1 Error induced by line pressure changes
Constant Temperature with Varying Pressure
Pressure Temperature PulsesSCF Error
50 60 2556027821 1546
51 60 2517123288 1370
52 60 2479385307 1199
53 60 2442762186 1034
54 60 240720524 873
55 60 237266858 717
56 60 2339108911 566
57 60 2306485356 418
58 60 2274759285 275
59 60 2243894166 136
60 60 2213855422 000
61 60 2184610304 132
62 60 2156127771 261
63 60 2128378378 386
64 60 210133418 508
65 60 2074968632 627
66 60 2049256506 743
67 60 2024173807 857
68 60 1999697703 967
69 60 1975806452 1075
70 60 1952479339 1181 Flow Measurement | K-Factor | Measurement
Accuracy | Turbine Flowmeter
Find related content flowcontrolnetworkcomhellipSearch on
FLOWSTREAM
Kevin Clark is senior develop-
ment engineer for Turbines Research
amp Development LLC Turbine RampD is a
subsidiary and the research and techni-
cal support arm of Turbines Inc which
serves a range of industries and applica-
tions from oil amp gas to cryogenic liquids
to custody transferKevin Clark
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2645
Pumps Bearings amp Seals TECHNOLOGY REPORT
FEATURES
SYSTEMS DESIGN
The ComplicatedCase of
Compressors
withSide-Streams
24 28 32BEST PRACTICES
How PumpingSystems
AffectSealing
Performance
TECH OUTLOOK
BearingSuppliers
Drive Gains InDeveloping
Markets
wwwflowcontrolnetworkcom January 2015 | 23
S P E C I AL S E C T I O N
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2745
The design and operation of compressors with side-
streams has always been difficult because flow entering the
compressor needs to be mixed with the core flow already
in the compressor (compressed in section-1) in a manner
that does not degrade the aerodynamic performance of sur-
rounding sections Minimizing losses and ensuring proper
mixing of the side-stream flow and core-flow are required to
ensure effective performance of a compressor of this sort
Key considerations for an application involving compres-
sors with side-stream flow include
The plant process typically dictates the side-stream
flange pressure
The impellers upstream of the side-stream should
achieve the necessary pressure for the core-flow
The side-stream flow is typically at a temperature dif-
ferent from compressor core-flow temperature
Process plants need some degree of operational flex-
ibility ie the ability to support variations in core-flow condi-
tions and side-stream conditions
Modern process plants are usually specifying more than
one operating conditions (sometimes two or more manda-
tory conditions) which can present challenges to compres-
sors with side-streams Adding to these issues modern
compressors should operate with much higher impeller tip
The COMPLICATED CASE ofCompressors with Side-StreamsConsidering key system design requirements
to ensure operational efficiency By Amin Almasi
4 January 2015
Flow Control Magazine
|
y
g
Some compressors in certain applications
have one or more incoming side-streams
(or side-loads) that introduce side-stream
flow to mix with the core flow In other words
a radial side-stream inlet is utilized in multi-
impeller centrifugal compressors to introduce
additional gas into the mid-stage of a com-
pressor This design enables optimization in
some process plants However the flow dis-
tribution after the junction of the side-stream
and the main return channel of the upstream
section can significantly affect the perfor-mance of the next section of compressor
In most cases the pressure levels at these
side-streams should be accurately predicted
to meet the theoretical performance
Compressor station at a natural gas processing plant
R U D M E R Z W E R V E R I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2845
speeds and inlet Mach numbers compared to previous
generations of compressor technology
Likewise side-streams are now com-
monly used with medium-sized and
large-sized compressors (eg 1ndash60
MW) The costs associated with cor-
rections on side-stream compres-
sor applicationsmdashany repair
inefficient operation and power
lossesmdashwould be very high Fur-
ther compressors with side-streams
are usually sensitive and difficult
machines to operate In particular
performance curves (performance
pressures efficiency etc) are sen-
sitive to suction inlet conditionsside-stream inlet conditions vol-
ume flow ratio (side-stream vol-
ume to core-flow volume) and side-stream losses
Compressors with side-stream often perform far below
expectations The main reason is that side-stream compres-
sors are different than conventional compressors (without
a side-stream) in design and operation For a compressor
with side-streams tighter tolerances in operating conditions
must be identified and applied Uncontrolled variations of
suction pressure or side-stream pressure are major prob-
lems Another major issue is the variations of the flow ratio
(side-stream flow to core-flow)
Compressor Side-Stream amp Mixing SectionIn many centrifugal compressors the portion of the side-
stream system from the flange connection to the mixing
section is similar to a compressor inlet A great challenge
is ensuring the mixing section provides circumferentially
uniform merged-flow with minimum losses This can be
achieved via effective design of the inlet configuration and
mixing section of the side-stream compressor such that
the impeller can be maintained over the whole operating
range of the compressor In many cases while there are
mixing sections provided for the machine the flows do not
completely mix before entering the impeller of the section-2
(the impeller after the mixing section) Non-uniformity at
inlet flow to the impeller is a key concern for compressor
performance
Another consideration is a compact design of the side-
stream mixing section Specifically a mixing section with
less axial length is always preferred This axial length can af-
fect the compressor rotor dynam-
ics the rotor length and over-
all compressor performance
(design cost operation and
reliability)
The side-stream exit pressure
(side-stream pressure at inlet
of the mixing section) is mainly
a function of the side-stream
flow velocity and the pres-
sure in the previous section of
the compressor Conversely the side-
stream flange pressure can depend on
side-stream flow velocity and section-1
exit conditions Therefore the side-stream
inlet flange volume flow is a function of theflange pressure compressibility (at that
pressure and temperature) and mass flow
Some engineers assume that the side-stream flange pres-
sure is equal to the inlet pressure of the first impeller of the
section-2 This is not true The mixed total pressure can be
estimated on a mass-averaged basis using side-stream total
pressure and return channel exit (section-1) total pressure
In some designs because of the lower static pressure at
the side-stream exit the total pressure at the return channel
exit is lower even though the velocity upstream is roughly
matched for both streams The pressure usually increased
at the returned channel but it can be reduced again at the
side-stream exit While simple in nature this can have an
impact on the prediction of pressure at the side-stream exit
and overall mixing section performance Based on basic flow
principles it was usually assumed that the static pressure
was equal between both flow streams at the mixing location
While this assumption might be used in rough calculations
the accurate simulations have shown this assumption is not
true In fact there are some points (for instance the shroud
wall at the exit of the return channel and the hub wall at
the exit of the side-stream) where this assumption is true
However this is not valid for all locations There are pressure
changes that occur from a side-stream flange to the inlet
of the next section (section-2) which depend on different
factors The first factor is the frictional losses due to side-
stream geometry from side-stream flange to plenum mix-
ing section etc The other factors are pressure changes due
to local curvature and geometry details of mixing section
Another consideration is the operation of a compressor
with side-stream at part-load The performance of the side-
wwwflowcontrolnetworkcom January 2015 25
Figure 1 An example of a centrifugalcompressor with side-stream
COURTESY SIEMENS
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 29456 January 2015
Flow Control Magazine
|
y
g
stream path the mixing section and
the downstream impellers when ma-
chine is operated at part-load or even
off-design operating flows will result
in additional compressor performance
problems In such a case both veloc-
ity profiles and pressure variations in
various parts (side-stream path mixing
section etc) will be different resulting
in complicated flow patterns and com-
plex aerodynamics behaviors
Side-Stream CompressorSectional Performance
Typically vendor-supplied compressor
performance curves reflect flange-to-flange performance because that is
what the plant engineers need to
evaluate the proper operation of their
system (for example from suction to
side-stream and from side-stream to
discharge) In many cases compres-
sor vendors also provide the over-
all compressor performance curves
and performance curves for section-1
(from suction to side-stream) and sec-
tion-2 (from side-stream to discharge)
Flange-to-flange data if not interpret-
ed properly can lead to false conclu-
sions about the relative performance
of individual sections of a compression
system For example if side-stream
losses from the flange to mixing sec-
tion are attributed to the downstream
section (section-2) it will cause the
downstream section (section-2) to
appear low in performance while the
upstream section (section-1) will show
high performance levels
An important behavior to con-
sider is when the actual side-stream
pressure is different than the rated
side-stream pressure When the side-
stream pressure is slightly higher than
the outlet pressure of the section-1
it (section-1) shows a relatively higher
performance compared to the real sec-
tion-1 performance In some cases
the performance of section-1 could be
considerably higher than section-2 In
other words when performance is de-
termined flange to flange the higher
flange pressure is seen as extra ldquopseu-
dordquo work done by the section (since this
is an inconsistent thermodynamic vol-
ume) resulting in a relatively high sec-
tional efficiency (section-1 shows a rel-
atively high efficiency) This is the case
for many compressors with side-stream
because the whole system is designed
(or specifically the side-stream location
is selected) in a way aimed at main-
taining the real side-stream pressure(side-stream inlet) above the section-1
outlet pressure because if the real side-
stream pressure becomes lower than
the section-1 outlet pressure the flow
may (theoretically) reverse
This is particularly important when
the side-stream mass flow is much
lower than the mass flow of core-flow
The above-mentioned reasons explain
why in many simulations calcula-
tions and performance reports related
to compressors with side-stream the
section-1 shows a relatively good ef-
ficiency and section-2 appears low in
efficiency
When the side-stream pressure is
slightly lower than the outlet pressure
of the section-1 the section-1 might
show a relatively lower performance
compared to section-2 This could oc-
cur in some recycle services where the
side-stream is actually a recycle flow
with a mass flow around two to five
times the core-flow The side-stream
(recycle) flow is returned from down-
stream of the compressor to be slightly
compressed and recycled to the down-
stream Such a recycled side-stream
compressor can present unique chal-
lenges for design and operation This
kind of machine usually needs very
special operating procedures and very
fine adjustments regarding operating
pressures and flows
Side-Stream Compressor
Performance amp Operation An important consideration is the sen-
sitivity of compressor overall perfor-
mance curve and sectional perfor-
mance curves to the flow ratio (ratio
of side-stream flow to core-flow) and
to the inlet conditions Variations in
the flow and pressure of the main
suction and side-stream inlet should
be controlled within tight tolerances
For compressors with side-stream the ASME PTC-10 code stipulates limits on
flow ratio (side-stream volume to core-
flow volume) The acceptable variation
in volume flow ratio in a compressor
with a side-stream is +-5 percent as
per ASME PTC code The requested
side-stream pressure tolerance is not
usually specified in compressor codes
but it should be around +- 2 percent
(or sometimes +- 25 percent)
Variance in flow ratio impacts the
velocity levels where the two streams
merge Significant variation in the ve-
locity profile upstream of the impeller
changes the incidence on the blade
leading edge of the following impel-
ler This change in incidence leads to a
change in sectional performance over-
all compressor performance and train
efficiency
If the flow ratio is varied between 95
percent and 105 percent (tolerances
specified in the ASME PTC-10 code)
the flange pressure changes accord-
ingly resulting in a change in the sec-
tional performance and overall perfor-
mance The sectional efficiency varies
sometimes more than +- 4 percent
This variance reduces as the flow is de-
creased toward surge However as the
flow is increased toward overload the
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3045wwwflowcontrolnetworkcom January 2015 27
variance increases up to higher values
(even in some cases three to five times
compared to variations near the surge
zone) For example in a case study
for a compressor with side-streams a
+- 5 percent variation in flow ratio and
associated changes (pressures losses
etc) the sectional efficiency reduced by
approximately 34 percent at the rated
flow at allowable operating points at
the end of curve (near the overload
ie choke) efficiency reduced by ap-
proximately 55 percent These results
show that the variation in sectional
performance and overall performance
due to flow ratio is highest at operat-ing points near the overload and low-
est at operating points near the surge
For compressors which work most of
the time at high flow (flow higher than
rated flow and discharge pressure low-
er than rated pressure) the effects of
flow ratio deviations (and subsequently
efficiency reduction) would be higher
than compressors working on the left-
hand side of curve (say with sufficient
margins near the surge)
In the compressor codes (such as
API 617) the compressor power varia-
tions should be maintained below 4
percent However in some applica-
tions clients require tighter tolerances
on the consumed power sometimes
below 2 percent (or even below 15
percent) Some studies suggest while
+- 5 percent of volume flow ratio is
suitable for performance test as per
ASME PTC-10 code some plants re-
quire tighter control on the consumed
power and compressor performance
(lower limits on the efficiency) the tol-
erances on the volume flow ratio could
be tighter than ASME PTC code In this
regard +- 4 percent tolerance can be
suggested on the volume flow ratio (ra-
tio of side-stream flow to core-flow) of
compressors with side-streams
Based on operational experiences
acceptable variations in volume flow
ratio and inlet pressures (suction inlet
and side-stream inlet) of a compressor
with side-streams are +- 4 percent
and +- 2 percent respectively
Another important consideration is
the required adjustments for the flow
ratio (side-stream flow to core-flow)
Compressors with side-stream usually
require fixed side-stream flange pres-
sures For a compressor with some variations in operation conditions (even
small changes) it is not usually pos-
sible to achieve optimum operation by
keeping the flow ratio (side-stream to
core-flow) constant The flow ratio has
to be adjusted according to the inlet
flow at which the machine is operating
in order to get the required correspond-
ing side-stream flange pressure
Thermal changes have also been
known to cause some instability in
centrifugal compressors An example is
the thermal-induced change of resid-
ual unbalance For compressors with
side-streams which feature tempera-
ture differences between core-flow and
side-stream flow the thermal behav-
ior of the compressor is usually more
complex and requires more attention
Heavy Gas ChallengeHeavy gases (such as heavy hydrocar-
bon gases eg propane propylene
MTBE (Methyl Tertiary Butyl Ether))
have very low gas sonic velocities that
produce high Mach numbers in the
aerodynamic flow paths For these
services because of high Mach num-
ber high flow coefficient stages have
very narrow flow maps characterized
by limited surge and choke margins
Compressors with side-streams in
these services present great challeng-
es This is to say the side-streams and
associated mixing further complicate
design operation and performance
prediction because the pressure tem-
perature and flow conditions at each
one of these side-streams as well
as at the exit of the machine require
stringent tolerances to optimize the
overall efficiency and performance
As such it is important to accuratelymodel design operate and moni-
tor performance characteristics of any
impellers diffusers return channels
and generally all flow-path components
in a compressor with side-stream FC
Amin Almasi
is a senior rotating
machine consultant
in Australia He is
a chartered profes- sional engineer of
Engineers Australia
(MIEAust CPEng ndash
Mechanical) and
IMechE (CEng MIMechE) holds
bachelorrsquos and masterrsquos degrees
in Mechanical Engineering and is
a registered professional engineer
in Queensland He specializes in
rotating machines including cen-
trifugal screw and reciprocating
compressors gas turbines steamturbines engines pumps subsea
offshore rotating machines LNG
units condition monitoring and reli-
ability Mr Almasi is an active mem-
ber of Engineers Australia IMechE
ASME and SPE He can be reached
at aminalmasiymailcom
Amin Almasi
Compressor | Gas Flow | Performance Curve | Side-Stream Flow
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3145
The pressure in the stuffing box
containing the packing can be estimat-
ed by the following equation
SBP = [Discharge ndash Suction] 3 + Suction
Pressure at the bottom of the stuff-
ing box will be higher than the suction
pressure but considerably lower than
the discharge pressure It should be
noted this calculation will yield a con-
servative estimate of stuffing box pres-
sure that can be further reduced by
pump design
A hole in the stuffing box serves as
a port for injecting clean fluid that cir-
culates around a lantern ring aligned
under the flush port The fluid flushes
solids back into the process to protect
the packing from abrasive wear If the
clean fluid is injected at a pressure ex-
ceeding that at the bottom of the stuff-
ing box some of it will leak back into
the process and some will leak out to
the atmosphere Recommended flush
injection pressure is 15ndash30 PSI (1ndash2
Bar) greater than the pressure at the
bottom of the stuffing box
Fluid injection is also used to lubri-
cate and cool dry-running packing that
is subject to frictional heat and to pre-
vent air from entering the pump which
reduces flow and operating efficiency
Centrifugal pumps utilize three
types of impellersmdashopen semi-open
and closed (Figures 2 3 amp 4) Open
designs prevent fluids with large solids
from clogging the impellers but at theexpense of pump efficiency Backing
plates on semi-open designs serve to
trap the fluid for more efficient opera-
tion Closed impellers are for use with
clean fluids since solids could ac-
cumulate in the eye which would re-
quire tearing down the pump to remove
them
Single-Stage CentrifugalPumpsSingle-stage centrifugal pumps typi-
cally have good bearing support of the
shaft with few run-out or ldquowhiprdquo prob-
lems However in some cases they
are subject to cavitation This occurs
in the eye of the impeller where the
fluid is under vacuum If the pressure
is low enough it will cause the material
to vaporize forming air or water vapor
bubbles As the fluid passes through
How Pumping Systems Design Affects Sealing Performance
By Chris Boss
8 January 2015
Flow Control Magazine
|
Understanding how different types of pump designs impact
sealing is critical to optimizing efficiency safety and lon-
gevity of the sealing system Used for a wide variety of media
including clear fluids solutions and slurries single-stage
centrifugal pumps are one of the most common
types (Figure 1) Fluid drawn into these pumps
enters the eye of an impeller that spins itto the outside of its container
or volute building pressure as
it moves toward discharge
Some of this fluid will work
its way behind the impeller
where it must be sealed with
compression packing or a
mechanical seal
Figure 1
Figure 2 Figure 3 Figure 4
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3245
the pump under increasing pressure
these bubbles implode sending shock
and vibration through the impeller
adversely affecting the seal This phe-
nomenon can be mitigated by running
the pump at slower speed and higher
pressure at the suction end to prevent
air from entering the fluid
Double-Ended Split-CasePumpsOperating on the same centrifugal prin-
ciple but slightly different geometry are
double-ended split-case pumps (Figure
5) Fluid enters both ends of the pump
and is directed into the eye of an impel-ler which spins it out of the volute to
discharge Packing is installed on both
the shaft and bearing ends so the stuff-
ing box is exposed only to suction pres-
sure which is usually quite low
Axial Flow Pumps Axial flow pumps operate like hydro
turbines in reverse whereby a propeller
(or axial impeller) pushes the fluid to
discharge (Figure 6)
Since the stuffing box is located
downstream of the propeller at the dis-
charge end of the pump the packing is
exposed to the full discharge pressure
Vertical PumpsVertical turbine pumps are typically
flange-mounted on a floor extending
downward into a water-filled sump
hole (Figure 7) Available as single- or
multi-stage pumps they feature an
impeller or series of impellers rotated
simultaneously by a single shaft The
impellers increase the pressure of the
upward flow subjecting the stuffing box
to full discharge pressure
Vertical pumps can be quite long so
inadequate bearing support can cause
the shaft to run out This can induce
undesirable lateral motion on the pack-
ing Worse the packing may be forced
to serve both as a bearing and a seal To
withstand these conditions the packing
should be resilient elastic and resistant
to deformation These properties rule
out packing such as graphite foil in favor
of fiber-based materials
Multi-Stage PumpsMulti-stage pumps are used for high-
pressure applications such as feeding
the boilers in steam-powered generating
plants Stuffing box pressure can vary
with pump design and number of stag-
es Designed for clean fluids and high
operating speeds these pumps typically
have high- and low-pressure ends with ahydraulic pressure equalization line run-
ning between the stuffing boxes
Like vertical pumps multi-stage
pumps feature a series of impellers to
build fluid discharge pressure In the
case of the six-stage pump pictured in
Figure 8 fluid enters at the drive end
where a stuffing box is exposed to suc-
tion pressure Channeled from one
impeller to the next through the pump
casting the fluid can reach extremely
high pressures at discharge
A second stuffing box located at the
bearing end is exposed to an intermedi-
ate pressure from the third impeller This
pressure is greater than the suction pres-
sure but much less than the discharge
pressure which can reach 2000 PSI
Fortunately the stuffing boxes in
these pumps are not exposed to dis-
charge pressures and typically see be-
low 500 PSI which is within the range
of some packing materials
wwwflowcontrolnetworkcom January 2015 29
Figure 5
Figure 6
Figure 7
Figure 8
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 33450 January 2015
Flow Control Magazine
| Gear PumpsPositive-displacement or gear pumps
operate on a different principle than
centrifugal pumps In external gear
pumps the fluid flows around the out-
side of the gears the intermeshing
of which forces it through the pump
to discharge (Figure 9) This design
makes these pumps particularly suit-
able for use with highly viscous fluids
such as resins emulsions syrups and
adhesives As such they are used for
transfer or metering applications
It should be noted gear pumps will
continue to displace fluid as long as
their shafts are turning which can pose
a problem if a clog occurs at the dis-
charge The resulting buildup of pres-
sure can blow out seals and damage
the pump Therefore most gear pumps
have pressure relief valves to divert
fluid back to the suction side for re-
circulation through the pump Internal
gear pumps operate slightly differently
but also have pressure relief valves to
prevent damage from excessive pres-
sure (Figure 10) In both external and
internal gear pumps the maximum
stuffing box pressure is determined by
these valves
Other rotating equipment includes
mixersagitators which are similar to
pumps in terms of the speeds to which
the packing is exposed There are ba-
sically three types of mixersagitators
top- bottom- and side-entry Top-entry
models are subject to the same con-
cerns about shaft run-out ldquowhiprdquo and
lateral forces on the paddles that are
encountered in some vertical pumps
Although some fluid may splash onto
the packing these mixers basically run
dry so the packing must have the abil-
ity to dissipate the resulting frictional
heat
In bottom-entry mixers the packing
is always exposed to fluid and may also
be exposed to solids requiring abra-
sion-resistance If the seal fails the en-
tire contents of the tank will eventually
drain out onto the bearings the floor
and other components under the stuff-
ing box
The packing in side-entry mixers may
be fully or intermittently exposed to flu-
id as well as side loading and vibration
Aside from media temperature
speed and other application variables
the configurations and operating prin-
ciples of rotary-type pumps exert differ-
ent forces on the seals used to keep
them from leaking These forces can
spell the difference between accept-
able seal performance and failure
Understanding these differences has
important implications that should be
taken into account to assure proper
sealing selection for long-term trou-
ble-free performance FC
wwwgarlockcom
Chris Boss is
a senior applica-
tions engineer for
Garlock Sealing
Technologies in
Palmyra NY He
has held various
positions in produc-
tion engineering
product development and applica-
tions engineering for the companyrsquos
compression packing division He
is a BSME graduate of the State
University of New York at Buffalo Mr
Boss can be reached at 800 448-
6688 or chrisbossgarlockcom
Chris Boss
Cavitation | Centrifugal Pump | Pump Packing | Sealing System
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Figure 9
Figure 10
Aside from media temperature speed and
other application variables the configurations
and operating principles of rotary-type
pumps exert different forces on the seals used
to keep them from leaking These forces can
spell the difference between acceptable seal
performance and failure
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3445
NS IDERNDUSTRIAL AUTOMATION + PROCESS CONTROL
WANT
INFORMATION
ON THE
automationindustry
SUBSCRIBE NOW at wwwiainsidercouk
Published by Spitzer and Boyes LLC Write in 15 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3545
Frost says the push from developing
economies is important as the market
is technologically mature and seeing
restricted growth in developed econo-
mies This is particularly true in Europe
and North America where recent finan-
cial insta-
bility has
reduced capital expenditure across end-
user industries
Bill Moore senior vice president of
sales development and channel man-
agement for global bearings manufac-
turer SKF says ldquosmartrdquo products and
the expansion of robust reliability pro-
grams are helping to drive new invest-
ment particularly in developed coun-
tries where the cost to compete is
high Frost says the magnitude of
the existing global installed base will
strengthen the need for replacement
and upgrades adding to market de-
mand as well
Frost says despite the potential
in developing economies the focus
on price as a product differentiator
may lead to intense price pressures
among manufacturers and bring down
the value of the overall market in the
short term The growing trend among
consumers to choose low-cost Chinese
imports will complicate this challenge
As price and quality become stan-
dardized across the globe customers
will base more of their purchasing deci-
sions on value-added services accord-
ing to Frost This will push manufactur-
ers to create more maintenance-free
solutions such as lubrication-free
bearings that offer end-users savings
on service and replacement costs and
reduce downtimeldquoOffering a complete line of prod-
ucts with comprehensive services will
be another feather in the cap of ven-
dors looking to widen their consumer
baserdquo notes Frost Industrial Automa-
tion and Process Control Research
Analyst Guru Mahesh
Moore says the trend of outsourcing
manufacturing to regions where labor
and production costs are favorable is
becoming less of a factor
ldquoThe days when cheap labor made
a significant difference in where a prod-
uct is manufactured mdash particularly high
value-added products or high weight
and bulk products mdash are coming to
an end as the cost of transportation
storage and inventory balance out the
benefits of production costs where la-
bor is a smaller percentage of the cost
of manufacturingrdquo Moore says ldquoLocal
manufacturing development will indeed
come to developing countries as their
ability to create markets that generate
economies of scale that support local
production is a clear trend and one that
all manufacturers will pay attention tordquo
Moore says that development of
maintenance-free or predictive tech-
nologies and products will be a sig-
nificant advantage to everyone in the
Bearing amp Coupling Manufacturers Focus
onDEVELOPING Economies
amp EFFICIENCY InnovationBy Amy W Richardson
2 January 2015
Flow Control Magazine
|
gy
Anew study from Frost amp Sullivan (wwwfrostcom) fore-
casts steady growth for the overall bearings and couplings
market based on rapid industrial development in high-growth
regions Specifically Frost predicts development in Mexico
Indonesia Nigeria Turkey Brazil Russia India and Chinawill help boost the bearings amp couplings market from $2206
billion in 2013 to an estimated $2676 billion in 2018
The development of maintenance-freeor predictive technologies will helpboost growth in the bearings market For example SKF is developing products that will automatically notifyusers when a bearing or mechanicalrotating component is approachingthe end of its useful life Pictured hereis an SKF Microlog analyzer a por- table condition monitoring tool
COURTESY SKF
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
improved productivity through simplified solutions The powerful technology and tools ensure repeatable
reliable accurate measurements Easier access to process data allows for better troubleshooting process
optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
For daily product notes visit the lsquoFeatured Productsrsquo section flowcontrolnetworkcom
ON THE WEB
1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3845
FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
and benefits as well as grids of
instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
services provided for the
mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
Brought to you by Beamex
Your Source For Fluid Handling Videos
Go towwwflowcontrolnetworkcomfreeinfo
Select appropriate issue ofFlow Control Magazine
Select advertisements thatinterest you
Enter your email amp clickldquoSubmit Requestrdquo
1
2
3
4
PRODUCT
INFORMATION
ONLINE
Follow these 4 steps to receive freeproduct information from suppliers
FREE
FEATURED VIDEO How to Calibrate aPressure Measurement Loop
For more information about FlowTube
sponsor packs email FlowControlGrandViewMediacom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4245
THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
Name ________________________________________________________________
Title _________________________________________________________________
Company _____________________________________________________________
AddressCityStateZip __________________________________________________
______________________________________________________________________
Phone ________________________________________________________________
E-Mail ________________________________________________________________
One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545
![Page 15: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/15.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1545
of hydrocarbon mixtures into pure components
However researchers say an innovative solution may
have come in the form of a novel chemical sponge This
porous material a metal-organic framework was devel-
oped by the same team at Nottingham just two years ago
Now in research published in Nature Chemistry for the
first time scientists have proven that it can be used toseparate hydrocarbon mixtures without the need for high
process pressures or very low process temperatures
Reusable MaterialsMade from cheap organic materials aluminum nitrate
salt and water the porous material called NOTT-300 is
able to adsorb different gases found in mixtures of hydro-
carbons at different rates making it possible to sepa-
rate them and extract the most useful ones NOTT-300
requires less energy to function than existing methods
as it operates at ambient temperatures and normal pres-
sures researchers say The gases that are adsorbed intoNOTT-300 can be removed without a significant energy
input and therefore the material can be easily reused
The team of scientists from Nottingham used Diamond
the UKrsquos synchrotron science facility as well as STFCrsquos
ISIS Neutron Facility and Oak Ridge National Laboratory
the UKrsquos and USArsquos world-leading neutron facilities re-
spectively to prove that the sponge works under real-life
conditions
Professor Martin Schroumlder Dean of the Faculty of Sci-
ence at Nottingham said in the news release ldquoIt is a very
important to be able to separate different hydrocarbons ef-
fectively and efficiently with low-energy consumption Po-rous solids such as the metal-organic framework system
studied here represent important materials for the future
development of low-energy separation technologies We
are most grateful to our collaborators at ISIS Neutron Fa-
cility Oak Ridge National Laboratory and Diamond Light
Source in bringing this work to fruitionrdquo
Significant Impact on Oil IndustryDr Sihai Yang the winner of Diamond Young Scientist
and BTM Willis Prize is a Senior Research Fellow at
Nottingham He led the project together with Professor
Martin Schroumlder Yang said ldquoWith the help of advancedcentral facilities like Diamond ISIS and ORNL we have
developed a new separation technique which can poten-
tially reduce the energy usage associated with oil petro-
leum and chemical industries which require the separa-
tion of raw hydrocarbons from crude oil
The discovery of the new material NOTT-300 could
have a significant impact on the oil industry by removing
the necessity for some energy-intensive refinement pro-
cesses researchers say
The research was funded by Engineering and Physical
Sciences Research Council (EPSRC) the European Re-
search Council (ERC) The University of Nottingham andLeverhulme Trust
12 | January 2015
Flow Control Magazine
Write in 21 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
No media contact - No risk of leaks
No process Shut-Downs for installation
No bypass needed
For hazardous area locations (FM approved)
Monitor your Total Acid Consumption
Increase your Plant Up-Time
Balance your Processes
PIOXreg S
PIOXreg S - the evolution of flow and concen-
tration measurement in acid production
Non-intrusive mass flow concen-
tration and density measurement
of aggressive media
wwwpiox-scom
wwwfleximcom
Contact us for a free trial measurement
Thank you for your votes and
making PIOXreg S a Flow Control
Awards Winner
THE OUTLOOK | News amp Notes
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1645
The ASCO trademark is registered in the US and other countries The Emerson logo is a trademark and service mark of Emerson Electric Co copy 2014 ASCO Valve Inc
1-800-972-ASCO (2726) | e-mail info-valveascocom | wwwascovalvecomSpoolValve
Now get spool valves with industry-leading ASCO solenoid technology built in
Delivering unmatched performance and durability our compact new valves are
perfect fits for all your onshore near-shore or offshore upstream control panels A
range of easily configured features and options includes superior temperature and
pressure ratings plus low-power models The industryrsquos toughest testing ensures
every rugged stainless steel valve meets or exceeds specifications Plus we design
and support every spool valve we make Ask for ASCO the ultra-reliable choice for oil
and gas control panels
These new spool valves will fit right in
Write in 22 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 174514 | January 2015 Flow Control Magazine
PPLICATIONS CORNER | Process Instrumentation
This is the final article in a series based on the troubleshoot-
ing of a mysterious unit shutdown due to flowmeter perfor-
mance problems
If yoursquove followed this column for most of 2014 you know
that what should have been a liquid ammonia stream to the
feed plant became problematic due to the occurrence of
bubbles of ammonia gas These bubbles caused an ultrasonic
flowmeter in a unit to indicate zero flow and caused the reactor
to scram (shut down) under warm operating conditions The source of the bubbles was traced back to the pres-
sure drop associated with a control valve located at the
exit of the liquid ammonia tank farm
This issue was resolved by identifying the problem
and fixing it at its source This was a pragmatic ap-
proach at the time (early 1980s) given the operation
of the cooling system in the unit and the limited selec-
tion of applicable flowmeter technologies
By the early 1990s changes were implemented that elim-
inated all process cooling requirementsmdashexcept for the small
jacketed cooler upstream of the liquid ammonia flowmeter In
other words after these changes the entire cooling system
would be operated and maintained to cool a few meters of
one small ammonia pipe Coincidently at about the same
time Coriolis mass flowmeters became more mature and
could reasonably measure the mass flow of liquid streams
with homogeneous low levels of vapor
The convergence of these two events resulted in another
approach to the problem that was not available in the early
1980smdashie install a Coriolis flowmeter that could operate in
the presence of bubbles The purchase and installation of a
Coriolis mass flowmeter was given high priority given its im-pact on unit operation economics and safety (by eliminating
the ldquomidget-makerrdquo (see March 2014 page 14))
Plant requirements and the technology that can meet
plant needs keep changing An excellent solution today can
become outdated in just a few years However there are few
substitutes for understanding fundamentals when addressing
a problem In other words there can be more than one way
to skin a cat FC
wwwspitzerandboyescom
Problem Solved AgainA Coriolis mass flowmeter provides a better solution
F o r B e t t e r P i p i ng S y s t e m P e r f o r m a nc e hellipFor Better Piping System Performancehellip
I d e a l f o r Ag g r e s s i v e C h e m i c a l s
1384 POMPTON AVENUE CEDAR GROVE NEW JERSEY 07009
973-256-3000 bull Fax 973-256-4745www p l as t om a t ic co m bull i n f o p la s t om a t ic co m
bull Rugged thermoplasticshandle corrosive andultra-pure chemicaltreatments
bull Constant pressure enhances
pump performancebull Prevents overpressure in
piping system
bull Wide range of pressuresettings
bull PTFE shaft and diaphragm designs
bull 1 4rdquo - 3rdquo sizes in PVC CPVC PVDFPolypro and PTFE
bull First State approved
thermoplastic valve for
anti-siphon applications
Write in 10 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
David W Spitzer
Ammonia Gas | Coriolis Flowmeter | David W Spitzer | Scram | Troubleshooting
FLOWSTREAM Find related content flowcontrolnetworkcom
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and Boyes
LLC offering engineering seminars strategic marketingconsulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer can be reached at 845 623-
1830 or at wwwspitzerandboyescom
The purchase and installation of a
Coriolis mass flowmeter was given
high priority given its impact on unit
operation economics and safetyldquordquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1845
Smart Valve Positioner
Beyond Control The NEW Research Controlreg SRD positioner does
everything you expect any valve positioner to do
plus more The SRDrsquos comprehensive diagnostics tool
continuously monitors for fugitive emissions delivers
real-time performance statistics and facilitates both
proactive and reactive process management Available
with integrated network communications the SRD is
compatible with Research Control valves and most other
pneumatically-actuated valves
Visit wwwbadgermetercomSmart-Valve-Positioners or
call 877-243-1010 for more information today
copy 2015 Badger Meter Inc
RESEARCH CONTROL is a registered trademark of Badger Meter Inc
Write in 11 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1945
Process improvements to increase yield or cut manufactur-
ing costs typically require enhanced process control but the
installed base of measurement instrumentation in a process
plant may simply be unable to facilitate improvements because
of age inadequate performance or unreliability Maintenance
cost and unscheduled process downtime for an aging process
plant can be very damaging to the balance sheet Upgrading
to new more accurate and more reliable instrumentation can
be prohibitively expensive New plant construction must alsomaintain a focus on optimizing costs for the process control
infrastructure The budget approval decision for new plant
construction must weigh such costs against projected market
conditions for the products that the plant is intended to manu-facture In todayrsquos volatile global marketplace return on invest-
ment calculations for plant upgrade or new plant construction
projects may go through several iterations before the trigger is
finally pulled or indeed not pulled
This article describes advances in two-wire instrumenta-
tion specifically in relation to flowmeters that have taken
place in the past few years and the significant cost benefits
that this new technology can realize for plant builders and op-
erators in terms of capital investment and cost of ownership
The Significance of Two-Wire Loop Power
A survey involving 204 participants in the chemical indus-try across Germany Switzerland the UK Canada and the
United States (Manfred Koenig PhD KIM Ludwigshafen
Germany 2006) revealed an 87 percent preference for two-
wire instrumentation versus four-wire in process applications
and 89 percent for utilities This overwhelming preference
may stem from the fact that older process plants were built
with two-wire twisted-pair cable networks connecting all
process units and measuring instruments together in an
overall plant control scheme
However these existing cables are relatively unsophisti-
cated and incapable of supporting anything but low-energy
instrumentation that is insensitive to interference from otherelectrical sources that might be sharing the same cable con-
duit Further the low energy levels supported by these two-
wire loops are more easily rendered safe in terms of explo-
sive risk in hazardous areas containing flammable materials
Many older process plants are also likely to have a significant
installed base of flowmeters employing pre-war (pre-1945)
technology such as positive displacement (PD) turbine vari-
able area (VA or Rotameter) and differential pressure (dP)
Market data firm Flow Research Inc (wwwflowresearch
com) indicates collectively a future compound negative annual
growth rate approaching minus 3 percent to 5 percent for PD
turbine and VA flowmeter types while dP is expected to keeppace with market growth (World Market for Flowmeters 2010)
YSTEMS DESIGN | Flow Measurement
16 | January 2015
Flow Control Magazine
The Two-Wire
ADVANTAGENew wiring options enable modern instrumentsto drive cost savings in existing plant systems
By Steve Milford
Advances in two-wire instrumentation have enabled mod- ern technology to be employed to the advantage of older
plant and process systems
Some chemical manufacturing plants are
competing for survival not only externally
against other global companies but also
internally among the global facilities of theirown company Other industry sectors face
similar challenges
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2045wwwflowcontrolnetworkcom January 2015 | 17
The Need to Replace Older TechnologiesUntil the 21st century two-wire loops were only able
to support these relatively unsophisticated instruments
which convert their measurement by various means into a
4-20mA output or pulse signal to the control system The
more advanced post-war flowmeter technologies such as
Coriolis ultrasonic or electromagnetic flowmeters have
until just eight years ago required a dedicated power sup-
ply for their function in addition to the output loop and
thus a four-wire infrastructure was required as a minimum
Therefore upgrading older two-wire meter devices to moremodern four-wire technology could require significant
expenditure in terms of the installation of separate power
cables and supply modules
There was a major breakthrough in 2006 when a true
two-wire loop-powered inline liquid ultrasonic flowmeter
was introduced (Figure 1) The nature of this breakthrough
was innovation in device power management This was the
missing piece up to that point because to be a true loop-
powered device the meter had to directly provide a full 16
mA span using less than 36 mA of remaining loop current
and less than 1 Watt of electrical energy The flowmeter
operated on a single 4-20 mA HART two-wire loop wasremotely powered by a DC supply was certified Class 1 Divi-
sion 1 and could be deployed as Intrinsically Safe through
the use of an approved safety barrier
A true two-wire loop-powered Coriolis flowmeter followed
in 2011 (Figure 2) employing a new and more advanced
common electronics platform A two-wire loop-powered inline
ultrasonic flowmeter for low-pressure gas was introduced in
2012 and a second two-wire loop-powered Coriolis meter fol-
lowed in 2013 offering improved measurement performance
and an additional high-performance meter tube material
Electromagnetic and vortex flowmeters had already been
available for some years in two-wire loop-powered form butimproved performance resulted as these designs were incor-
COURTESYENDRESS+HAUSER
Figure 1 A two-wire ultrasonic flow- meter released in 2006 operated ona single 4-20 mA two-wire loop
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I I I I LL I
I I I I LL I
copy COPYRIGHT 2015 OMEGA ENGINEERING INC ALL RIGHTS RESERVED
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Prices listed are those in effect at the time of publication and are subject to change without noticePlease contact OMEGArsquos sales department for current prices
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Positive Displacement Flow Meterfor Fuels and Oils
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Thermal Imaging CameraFor Inspection andFactory Diagnosis
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 214518 | January 2015
Flow Control Magazine
porated into their new common electron-
ics platform in 2013 So all the ldquomodernrdquo
flow measurement technologies mdash that
is to say those introduced post-war mdash
have become available as two-wire loop-
powered devices with one exception
namely thermal mass (thermal disper-
sion) meters Unfortunately the power
requirements for this technology exceed
what is currently deemed possible withtwo-wire loop-power management
Payback forTechnology UpgradeConsider a 1rdquo process line
containing a liquid process
ingredient costing $1lb at a
mass flowrate of 150 lbmin-
ute We have $150minute
flowing in the line translating
to $9000hour and $72000
per eight-hour shift That cal-culates further to $360000
per five-day working week and
for a working year of 40 weeks for
example that is $144 million Assume
the existing device is a turbine flowmeter
Now imagine a two-wire loop-
powered Coriolis mass flowmeter is
installed in place of the existing meter
The line would need to be drained and
probably one process flange replaced
allowing the Coriolis to fit mechanically
in place of the turbine However thetwo-wire loop already used for carrying
the existing meterrsquos flow signal to the
control room can be used unaltered
for the complete electrical installation
aspects of the Coriolis flowmeter
The upside of the change is signifi-
cant and clear cut Assuming the exist-
ing meter measurement uncertainty was02 percent of reading then measure-
ment uncertainty improves through use
of Coriolis to 01 percent of reading
giving a 01100 x $14400000 im-
provement in control of the ingredient
annually or $14400 A two-wire Coriolis
mass flowmeter with 01 percent mass
flow accuracy would be paid for in ap-
proximately 6-8 months In practice the
improvement in measurement uncer-
tainty would be greater as the operator
would gain temperature and density in-formation from the Coriolis and the mea-
surement would be devoid of any fluid
property dependence Viscosity change
for example can have a major impact on
turbine meter performance Mechanical
wear and tear that turbine meters even-
tually experience which causes them to
under-register flow is precluded by mod-
ern devices like Coriolis
Furthermore if the process ingredient
was being blended with another then ad-
ditional process improvements could berealized through in-line blending control
using Coriolis technology for final density
as the control point It is possible to have
dual 4-20 mA outputs from two-wire
loop-powered meters but as the main
4-20 mA output representing the prima-
ry variable is also HART then an external
HART Loop Converter or HART IO card in
the control system can provide second-
ary tertiary and quaternary variables as
4-20 mA signals A Coriolis meter is trulya multi-variable device Certain two-wire
devices are also available with Profibus
or Foundation Fieldbus communication
Cutting Wiring CostsIn 2003 WIBEXERA (International
Instrument Usersrsquo Associations) Report
T 2732 X 03 was published and it pro- vided an average survey of prices quoted
in projects at that time for the provision
of power supplies for four-wire instru-
ments The price ranged from euro1200
to euro1800 per instrument depending
upon design and plant characteristics
for an average cost of euro1500 (about
$2000) It would be reasonable to
assume an inflationary factor of 2 per-
cent per annum giving an approximate
current-day figure of $2500
From another source within thechemical industry an estimation of
$40foot to $50foot was given for in-
stallation of four-wire cabling For a
linear 50-foot cable run with for ex-
ample a 10-foot vertical at each end
this equates to $3150 Actual costs
and budget estimates have been given
as high as $10000
The Extent of the Opportunity The modern post-war flow measure-
ment technologies have different powerrequirements and consequently they
are not all available for the
same size range in two-wire
loop-power form For example
two-wire Coriolis flowmeters
are limited to 2rdquo diameter
electromagnetic and inline
low-pressure gas ultrasonics
are limited to 8rdquo and vortex
and inline liquid ultrasonic are
limited to 12rdquo
Nevertheless for thechemical industry in particu-
lar perhaps two-thirds of the
process pipes in a plant will be no larger
than 2rdquo and even when the host process
pipe is larger a correctly sized flowmeter
can still be less than 2rdquo There is consid-
erable scope for two-wire loop-power to
deliver value for flow measurement ap-
plications with total safety
The virtues of Coriolis technology
have been covered but what about
other two-wire technologies An elec-tromagnetic flowmeter in two-wire form
YSTEMS DESIGN | Flow Measurement
In todayrsquos volatile global mar-
ketplace return on investment
calculations for plant upgrade or
new plant construction projects
may go through several itera-
tions before the trigger is finally
pulled or indeed not pulled
ldquo
rdquo
COURTESYENDRESS+HAUSER
Figure 2 Two-wire Coriolis flowme- ters became available in 2011
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2245
can be used on water wastewater or
a light water-based slurry provided the
fluid has around a 20 microSeimenscenti-
metre (microScm) electrical conductivity
A magnetic flowmeter is full bore un-
less flowrates dictate a reduced meter
size in the interests of performance and
so there are no intrusions into the flow
stream and no pressure loss An accu-
racy of 05 percent of reading is normal
from a two-wire magnetic meter and a
modest five diameters (5D) of straight in-let run is needed to avoid error from up-
stream flow disturbances When the fluid
exhibits insufficient conductivity then
the same performance and installation
requirements can be met by an inline ul-
trasonic flowmeter provided the liquid is
essentially clean and bubble-free
For gas or steam applications a vor-
tex meter is the normal choice Using a
built-in temperature sensor a two-wire
loop-powered vortex meter can calculate
mass flow of saturated steam using in-ternal steam tables An external pressure
input allows mass flow of steam to be ac-
curately calculated even when saturated
steam becomes superheated as can oc-
cur downstream of a pressure regulating
valve With mass flow known the vortex
meter can calculate energy and heat flow
A new and exciting development is
the ability of the vortex meter to indicate
wet steam and calculate dryness frac-
tion or steam quality For safety and ef-
ficiency saturated steam should be dry
and free from condensate that is to say
it should possess a high steam quality
factor However the dry or wet state of
saturated steam can sit on a knife-edge
and shift to the opposing state due to
the slightest change in process condi-
tions Rapid and reliable indication of
this change of state is now available
Perhaps the most astonishingachievement in the power management
of two-wire loop-power flowmeters is
that of the ultrasonic biogas meter It is
now possible not only to measure the
flow of wet dirty variable composition
and low-pressure anaerobic digester
gas landfill gas and coal bed methane
gas with a two-wire loop-powered ultra-
sonic flowmeter but also the same de-
vice uses an inbuilt temperature sensor
in combination with measured sound
velocity to calculate methane contentcalorific value and energy flow
Technology to Take UsForwardModern flow technologies provide instru-
ment engineers with vital self-monitoring
information The format of such infor-
mation is easier to understand and act
upon when presented in accordance
with harmonized international guidelines
for online plant asset management eg
NAMUR Standard 107
Continuous plain-text self-diagnostic
and process-related information with
suggested remedies (Figure 3) make it
possible for instrument engineers andoperators to take action at the appro-
priate time mdash immediately or during
the next scheduled shutdown mdash saving
time and money by knowing the exact
health of their measuring point and the
probable actions required to rectify any
abnormal conditions Device verifica-
tion offering third-party validated trace-
ability can be performed on demand ei-
ther locally or remotely from the control
room without the expense of a man in
the field Calibration is then avoided ordeferred without process interruption
Where a process plant has a large
installed base of older mechanical tech-
nologies the decision to embark upon a
program of replacement for plant mod-
ernization cannot of course be taken
easily There are the stocks of spare
parts to consider along with the plant
instrument technicians who are trained
on and at ease with the old devices
However a process plant that retains
the older technology going forward willbe at risk and may find it increasingly
difficult or even impossible to maintain
a cost position that competes effective-
ly in the global market FC
wwwusendresscom
wwwflowcontrolnetworkcom January 2015 | 19
Steve Milford
is a Flow Product
Business Manager
for Endress+Hauser
Inc in Greenwood
Ind He has been
involved in flow
measurement since
1983 and has been
actively involved with standards devel-
opment for flow technology within the
International Standards Organization
(ISO) and the British Standards
Institute Mr Milford can be reached
at stevemilfordusendresscom
Steve Milford
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Coriolis Flowmeter | Magnetic Flowmeter | Two-Wire | Ultrasonic Flowmeter | Vortex Flowmeter
Figure 3 A modern instrumentrsquos display module can provide continuous plain- text self-diagnostic and process-related information
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2345
The bottom line is the volume of gas under one set of
pressure and temperature conditions is not the same as it
would be for the gas under different conditions Why is thisimportant Without compensation for compressibility read-
ings taken by gas flowmeters can result in measurementsmdash
and costs to the buyermdashsignificantly lower or higher than they
should be
The flow of gas in a system can be accounted for and
reported in a number of ways such as by volume by mass
flowrate and by energy Inline turbine meters can offer both
reliability and accuracy in measuring gas flow when matched
with a monitor capable of calculating and displaying results
that have been adjusted for the nature of the gas and impor-
tantly the pressure and temperature
Measuring Flow with an Inline TurbineFlowmeter
With an inline turbine meter gas flows into the meter through
a length of piping that helps to pre-condition the flow by
reducing undesirable swirls and asymmetry Where consid-
ered necessary a flow straightener may even be installed in
line to create a uniform flow profile to the extent possible
As can be seen in Figure 1 a rotor support within the tur-
bine housing further conditions the flow and directs it through
the blades of the rotor High-precision ball bearings allow the
rotor to freely rotate on the shaft
The rotorrsquos rotational speed is directly proportional to the velocity of the fluid passing through the meter The rotor itself
incorporates magnets (or magnetic blades depending on thedesign) while the housing is non-magnetic
A proximity sensor (also known as a pickup coil) is located
in line with the rotor and detects the electrical pulses gener-
ated by the ferrous rotor spinning through the magnetic field
Each pulse represents a discrete volume of gas The out-
put frequency provides the indication of the gas flow rate and
the accumulated pulses over a specified time represent the
total volume of fluid for that measurement period
Need for Calibration The flowrate of the gas through the meter cannot be deter-
mined accurately unless the meter is calibrated The fac-tory calibration determines the meterrsquos constant known
as a K-factor which is then inputted into the gas monitor
PPLICATION NOTES | Flow Measurement
20 | January 2015
Flow Control Magazine
COMPENSATING for
Compressibility inMeasuring Gas Flow Why K-factor adjustment is essential foraccurate inline turbine flow measurement
Unlike crude oil and other liquid fossilfuels natural gas poses a challenge
in monitoring the quantity of gas flowing
through pipelines While liquids do not com-
press gases do and the mass flowrate of
gas being transmitted through gathering
lines depends on both the pressure and
temperature
By Kevin Clark
Figure 1 Internal components of a liquid turbine flowmeter
C O U R T E S Y
T U R B I N E S
I N C
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2445
Wondering Whether the
Pump Guy Seminar
Is for YouCheck out the ldquoPump Guy Insightsrdquo
video series flwctrlcompginsights
PUMP GUY INSIGHT 1NPSHa vs NPSHrmdashWhy all pumps need gauges
PUMP GUY INSIGHT 3How to Operate Your Pump at Best Efficiency
PUMP GUY INSIGHT 5Head vs Flow
PUMP GUY INSIGHT 2 Your Pumps Are Constantly Moving On Their Curves
PUMP GUY INSIGHT 4 The Role of the Pump Reliability Chain
PUMP GUY INSIGHT 6How to Read a Pump Curve
PARTNER SPONSORSFor more information and to register
for upcoming Pump Guy Seminars
visit FlowControlNetworkcomPumpGuy
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2545
PPLICATION NOTES | Flow Measurement
22 | January 2015
Flow Control Magazine
Gas flowmeters measure the actual volume of gas passing
through the meter per minute irrespective of pressure and
temperature1
The volumetric flowrate of a gas is often corrected to
ldquostandardizedrdquo conditions of pressure and temperature While
ldquostandardrdquo conditions can vary depending on the definition
in the US this typically means a pressure of 1473 PSIA(pounds per square inch absolute) and a temperature of 60 F
The flowrate measurement is reported in standard cubic feet
per minute (SCFM)
Compensating for changes in pressure and temperature is
critical Consider a meter system setup for flowing conditions
of 60 PSIG (pounds per square inch gauge) and 60 F and the
line pressure decreases to 50 PSIG while the temperature
remains constant The difference in SCFM between the two
is more than 15 percent which would cost the buyer more
for the gas than it should As Table 1 demonstrates even a
small variation in pressure will result in a surprisingly high er-
ror percentage
Automation of the K-Factor The K-factor is established by an initial factory calibration In
the case of a non-compensated flow monitor any variations
in pressure and temperature will result in manual adjust-
ments needed to the K-factor In order to maintain accurate
flow measurement users must monitor pressure and temper-
ature and make corresponding adjustments to the K-factor To eliminate these manual adjustments some suppliers offer
a flow monitor that automatically adjusts for any changes in
pressure and temperature
These monitors provide accurate flow measurement regard-
less of changing environmental conditions in some cases sup-
porting applications with pressures as high as 15000 PSIG and
temperatures between -350 F to 350 F with a standard accura-
cy of +-1 percent over a flow range of 05 ACFM to 650 ACFM
Final NotesDuring the operation of a flowmeter system the ability to obtain
a readout mdash and to adjust for line pressure and temperaturechanges mdash is sometimes compromised by a lack of electric
power This issue is especially true along gas pipelines in remote
areas To overcome this limitation some manufacturers have
designed low-powered flow monitors which can operate for up
to on year on a single lithium D-cell battery
It is important for users to recognize the effects of the
compressibility of gas As such the quantity of a gas flow-
ing through a gas flowmeter depends on the pressure and
temperature In order to ensure accuracy any flowmetering
system must employ a means to correct for these effects
Otherwise the readout is certain to be in error and could be
unnecessarily costing money This is particularly crucial onwellhead production and in billing scenarios FC
wwwturbinesincorporatedcom
Notations1 The measurement factor in the US is known as the
ACFM actual cubic feet per minute (Metric units are typically
ACMH actual cubic meters per hour)
Table 1 Error induced by line pressure changes
Constant Temperature with Varying Pressure
Pressure Temperature PulsesSCF Error
50 60 2556027821 1546
51 60 2517123288 1370
52 60 2479385307 1199
53 60 2442762186 1034
54 60 240720524 873
55 60 237266858 717
56 60 2339108911 566
57 60 2306485356 418
58 60 2274759285 275
59 60 2243894166 136
60 60 2213855422 000
61 60 2184610304 132
62 60 2156127771 261
63 60 2128378378 386
64 60 210133418 508
65 60 2074968632 627
66 60 2049256506 743
67 60 2024173807 857
68 60 1999697703 967
69 60 1975806452 1075
70 60 1952479339 1181 Flow Measurement | K-Factor | Measurement
Accuracy | Turbine Flowmeter
Find related content flowcontrolnetworkcomhellipSearch on
FLOWSTREAM
Kevin Clark is senior develop-
ment engineer for Turbines Research
amp Development LLC Turbine RampD is a
subsidiary and the research and techni-
cal support arm of Turbines Inc which
serves a range of industries and applica-
tions from oil amp gas to cryogenic liquids
to custody transferKevin Clark
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2645
Pumps Bearings amp Seals TECHNOLOGY REPORT
FEATURES
SYSTEMS DESIGN
The ComplicatedCase of
Compressors
withSide-Streams
24 28 32BEST PRACTICES
How PumpingSystems
AffectSealing
Performance
TECH OUTLOOK
BearingSuppliers
Drive Gains InDeveloping
Markets
wwwflowcontrolnetworkcom January 2015 | 23
S P E C I AL S E C T I O N
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2745
The design and operation of compressors with side-
streams has always been difficult because flow entering the
compressor needs to be mixed with the core flow already
in the compressor (compressed in section-1) in a manner
that does not degrade the aerodynamic performance of sur-
rounding sections Minimizing losses and ensuring proper
mixing of the side-stream flow and core-flow are required to
ensure effective performance of a compressor of this sort
Key considerations for an application involving compres-
sors with side-stream flow include
The plant process typically dictates the side-stream
flange pressure
The impellers upstream of the side-stream should
achieve the necessary pressure for the core-flow
The side-stream flow is typically at a temperature dif-
ferent from compressor core-flow temperature
Process plants need some degree of operational flex-
ibility ie the ability to support variations in core-flow condi-
tions and side-stream conditions
Modern process plants are usually specifying more than
one operating conditions (sometimes two or more manda-
tory conditions) which can present challenges to compres-
sors with side-streams Adding to these issues modern
compressors should operate with much higher impeller tip
The COMPLICATED CASE ofCompressors with Side-StreamsConsidering key system design requirements
to ensure operational efficiency By Amin Almasi
4 January 2015
Flow Control Magazine
|
y
g
Some compressors in certain applications
have one or more incoming side-streams
(or side-loads) that introduce side-stream
flow to mix with the core flow In other words
a radial side-stream inlet is utilized in multi-
impeller centrifugal compressors to introduce
additional gas into the mid-stage of a com-
pressor This design enables optimization in
some process plants However the flow dis-
tribution after the junction of the side-stream
and the main return channel of the upstream
section can significantly affect the perfor-mance of the next section of compressor
In most cases the pressure levels at these
side-streams should be accurately predicted
to meet the theoretical performance
Compressor station at a natural gas processing plant
R U D M E R Z W E R V E R I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2845
speeds and inlet Mach numbers compared to previous
generations of compressor technology
Likewise side-streams are now com-
monly used with medium-sized and
large-sized compressors (eg 1ndash60
MW) The costs associated with cor-
rections on side-stream compres-
sor applicationsmdashany repair
inefficient operation and power
lossesmdashwould be very high Fur-
ther compressors with side-streams
are usually sensitive and difficult
machines to operate In particular
performance curves (performance
pressures efficiency etc) are sen-
sitive to suction inlet conditionsside-stream inlet conditions vol-
ume flow ratio (side-stream vol-
ume to core-flow volume) and side-stream losses
Compressors with side-stream often perform far below
expectations The main reason is that side-stream compres-
sors are different than conventional compressors (without
a side-stream) in design and operation For a compressor
with side-streams tighter tolerances in operating conditions
must be identified and applied Uncontrolled variations of
suction pressure or side-stream pressure are major prob-
lems Another major issue is the variations of the flow ratio
(side-stream flow to core-flow)
Compressor Side-Stream amp Mixing SectionIn many centrifugal compressors the portion of the side-
stream system from the flange connection to the mixing
section is similar to a compressor inlet A great challenge
is ensuring the mixing section provides circumferentially
uniform merged-flow with minimum losses This can be
achieved via effective design of the inlet configuration and
mixing section of the side-stream compressor such that
the impeller can be maintained over the whole operating
range of the compressor In many cases while there are
mixing sections provided for the machine the flows do not
completely mix before entering the impeller of the section-2
(the impeller after the mixing section) Non-uniformity at
inlet flow to the impeller is a key concern for compressor
performance
Another consideration is a compact design of the side-
stream mixing section Specifically a mixing section with
less axial length is always preferred This axial length can af-
fect the compressor rotor dynam-
ics the rotor length and over-
all compressor performance
(design cost operation and
reliability)
The side-stream exit pressure
(side-stream pressure at inlet
of the mixing section) is mainly
a function of the side-stream
flow velocity and the pres-
sure in the previous section of
the compressor Conversely the side-
stream flange pressure can depend on
side-stream flow velocity and section-1
exit conditions Therefore the side-stream
inlet flange volume flow is a function of theflange pressure compressibility (at that
pressure and temperature) and mass flow
Some engineers assume that the side-stream flange pres-
sure is equal to the inlet pressure of the first impeller of the
section-2 This is not true The mixed total pressure can be
estimated on a mass-averaged basis using side-stream total
pressure and return channel exit (section-1) total pressure
In some designs because of the lower static pressure at
the side-stream exit the total pressure at the return channel
exit is lower even though the velocity upstream is roughly
matched for both streams The pressure usually increased
at the returned channel but it can be reduced again at the
side-stream exit While simple in nature this can have an
impact on the prediction of pressure at the side-stream exit
and overall mixing section performance Based on basic flow
principles it was usually assumed that the static pressure
was equal between both flow streams at the mixing location
While this assumption might be used in rough calculations
the accurate simulations have shown this assumption is not
true In fact there are some points (for instance the shroud
wall at the exit of the return channel and the hub wall at
the exit of the side-stream) where this assumption is true
However this is not valid for all locations There are pressure
changes that occur from a side-stream flange to the inlet
of the next section (section-2) which depend on different
factors The first factor is the frictional losses due to side-
stream geometry from side-stream flange to plenum mix-
ing section etc The other factors are pressure changes due
to local curvature and geometry details of mixing section
Another consideration is the operation of a compressor
with side-stream at part-load The performance of the side-
wwwflowcontrolnetworkcom January 2015 25
Figure 1 An example of a centrifugalcompressor with side-stream
COURTESY SIEMENS
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 29456 January 2015
Flow Control Magazine
|
y
g
stream path the mixing section and
the downstream impellers when ma-
chine is operated at part-load or even
off-design operating flows will result
in additional compressor performance
problems In such a case both veloc-
ity profiles and pressure variations in
various parts (side-stream path mixing
section etc) will be different resulting
in complicated flow patterns and com-
plex aerodynamics behaviors
Side-Stream CompressorSectional Performance
Typically vendor-supplied compressor
performance curves reflect flange-to-flange performance because that is
what the plant engineers need to
evaluate the proper operation of their
system (for example from suction to
side-stream and from side-stream to
discharge) In many cases compres-
sor vendors also provide the over-
all compressor performance curves
and performance curves for section-1
(from suction to side-stream) and sec-
tion-2 (from side-stream to discharge)
Flange-to-flange data if not interpret-
ed properly can lead to false conclu-
sions about the relative performance
of individual sections of a compression
system For example if side-stream
losses from the flange to mixing sec-
tion are attributed to the downstream
section (section-2) it will cause the
downstream section (section-2) to
appear low in performance while the
upstream section (section-1) will show
high performance levels
An important behavior to con-
sider is when the actual side-stream
pressure is different than the rated
side-stream pressure When the side-
stream pressure is slightly higher than
the outlet pressure of the section-1
it (section-1) shows a relatively higher
performance compared to the real sec-
tion-1 performance In some cases
the performance of section-1 could be
considerably higher than section-2 In
other words when performance is de-
termined flange to flange the higher
flange pressure is seen as extra ldquopseu-
dordquo work done by the section (since this
is an inconsistent thermodynamic vol-
ume) resulting in a relatively high sec-
tional efficiency (section-1 shows a rel-
atively high efficiency) This is the case
for many compressors with side-stream
because the whole system is designed
(or specifically the side-stream location
is selected) in a way aimed at main-
taining the real side-stream pressure(side-stream inlet) above the section-1
outlet pressure because if the real side-
stream pressure becomes lower than
the section-1 outlet pressure the flow
may (theoretically) reverse
This is particularly important when
the side-stream mass flow is much
lower than the mass flow of core-flow
The above-mentioned reasons explain
why in many simulations calcula-
tions and performance reports related
to compressors with side-stream the
section-1 shows a relatively good ef-
ficiency and section-2 appears low in
efficiency
When the side-stream pressure is
slightly lower than the outlet pressure
of the section-1 the section-1 might
show a relatively lower performance
compared to section-2 This could oc-
cur in some recycle services where the
side-stream is actually a recycle flow
with a mass flow around two to five
times the core-flow The side-stream
(recycle) flow is returned from down-
stream of the compressor to be slightly
compressed and recycled to the down-
stream Such a recycled side-stream
compressor can present unique chal-
lenges for design and operation This
kind of machine usually needs very
special operating procedures and very
fine adjustments regarding operating
pressures and flows
Side-Stream Compressor
Performance amp Operation An important consideration is the sen-
sitivity of compressor overall perfor-
mance curve and sectional perfor-
mance curves to the flow ratio (ratio
of side-stream flow to core-flow) and
to the inlet conditions Variations in
the flow and pressure of the main
suction and side-stream inlet should
be controlled within tight tolerances
For compressors with side-stream the ASME PTC-10 code stipulates limits on
flow ratio (side-stream volume to core-
flow volume) The acceptable variation
in volume flow ratio in a compressor
with a side-stream is +-5 percent as
per ASME PTC code The requested
side-stream pressure tolerance is not
usually specified in compressor codes
but it should be around +- 2 percent
(or sometimes +- 25 percent)
Variance in flow ratio impacts the
velocity levels where the two streams
merge Significant variation in the ve-
locity profile upstream of the impeller
changes the incidence on the blade
leading edge of the following impel-
ler This change in incidence leads to a
change in sectional performance over-
all compressor performance and train
efficiency
If the flow ratio is varied between 95
percent and 105 percent (tolerances
specified in the ASME PTC-10 code)
the flange pressure changes accord-
ingly resulting in a change in the sec-
tional performance and overall perfor-
mance The sectional efficiency varies
sometimes more than +- 4 percent
This variance reduces as the flow is de-
creased toward surge However as the
flow is increased toward overload the
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3045wwwflowcontrolnetworkcom January 2015 27
variance increases up to higher values
(even in some cases three to five times
compared to variations near the surge
zone) For example in a case study
for a compressor with side-streams a
+- 5 percent variation in flow ratio and
associated changes (pressures losses
etc) the sectional efficiency reduced by
approximately 34 percent at the rated
flow at allowable operating points at
the end of curve (near the overload
ie choke) efficiency reduced by ap-
proximately 55 percent These results
show that the variation in sectional
performance and overall performance
due to flow ratio is highest at operat-ing points near the overload and low-
est at operating points near the surge
For compressors which work most of
the time at high flow (flow higher than
rated flow and discharge pressure low-
er than rated pressure) the effects of
flow ratio deviations (and subsequently
efficiency reduction) would be higher
than compressors working on the left-
hand side of curve (say with sufficient
margins near the surge)
In the compressor codes (such as
API 617) the compressor power varia-
tions should be maintained below 4
percent However in some applica-
tions clients require tighter tolerances
on the consumed power sometimes
below 2 percent (or even below 15
percent) Some studies suggest while
+- 5 percent of volume flow ratio is
suitable for performance test as per
ASME PTC-10 code some plants re-
quire tighter control on the consumed
power and compressor performance
(lower limits on the efficiency) the tol-
erances on the volume flow ratio could
be tighter than ASME PTC code In this
regard +- 4 percent tolerance can be
suggested on the volume flow ratio (ra-
tio of side-stream flow to core-flow) of
compressors with side-streams
Based on operational experiences
acceptable variations in volume flow
ratio and inlet pressures (suction inlet
and side-stream inlet) of a compressor
with side-streams are +- 4 percent
and +- 2 percent respectively
Another important consideration is
the required adjustments for the flow
ratio (side-stream flow to core-flow)
Compressors with side-stream usually
require fixed side-stream flange pres-
sures For a compressor with some variations in operation conditions (even
small changes) it is not usually pos-
sible to achieve optimum operation by
keeping the flow ratio (side-stream to
core-flow) constant The flow ratio has
to be adjusted according to the inlet
flow at which the machine is operating
in order to get the required correspond-
ing side-stream flange pressure
Thermal changes have also been
known to cause some instability in
centrifugal compressors An example is
the thermal-induced change of resid-
ual unbalance For compressors with
side-streams which feature tempera-
ture differences between core-flow and
side-stream flow the thermal behav-
ior of the compressor is usually more
complex and requires more attention
Heavy Gas ChallengeHeavy gases (such as heavy hydrocar-
bon gases eg propane propylene
MTBE (Methyl Tertiary Butyl Ether))
have very low gas sonic velocities that
produce high Mach numbers in the
aerodynamic flow paths For these
services because of high Mach num-
ber high flow coefficient stages have
very narrow flow maps characterized
by limited surge and choke margins
Compressors with side-streams in
these services present great challeng-
es This is to say the side-streams and
associated mixing further complicate
design operation and performance
prediction because the pressure tem-
perature and flow conditions at each
one of these side-streams as well
as at the exit of the machine require
stringent tolerances to optimize the
overall efficiency and performance
As such it is important to accuratelymodel design operate and moni-
tor performance characteristics of any
impellers diffusers return channels
and generally all flow-path components
in a compressor with side-stream FC
Amin Almasi
is a senior rotating
machine consultant
in Australia He is
a chartered profes- sional engineer of
Engineers Australia
(MIEAust CPEng ndash
Mechanical) and
IMechE (CEng MIMechE) holds
bachelorrsquos and masterrsquos degrees
in Mechanical Engineering and is
a registered professional engineer
in Queensland He specializes in
rotating machines including cen-
trifugal screw and reciprocating
compressors gas turbines steamturbines engines pumps subsea
offshore rotating machines LNG
units condition monitoring and reli-
ability Mr Almasi is an active mem-
ber of Engineers Australia IMechE
ASME and SPE He can be reached
at aminalmasiymailcom
Amin Almasi
Compressor | Gas Flow | Performance Curve | Side-Stream Flow
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3145
The pressure in the stuffing box
containing the packing can be estimat-
ed by the following equation
SBP = [Discharge ndash Suction] 3 + Suction
Pressure at the bottom of the stuff-
ing box will be higher than the suction
pressure but considerably lower than
the discharge pressure It should be
noted this calculation will yield a con-
servative estimate of stuffing box pres-
sure that can be further reduced by
pump design
A hole in the stuffing box serves as
a port for injecting clean fluid that cir-
culates around a lantern ring aligned
under the flush port The fluid flushes
solids back into the process to protect
the packing from abrasive wear If the
clean fluid is injected at a pressure ex-
ceeding that at the bottom of the stuff-
ing box some of it will leak back into
the process and some will leak out to
the atmosphere Recommended flush
injection pressure is 15ndash30 PSI (1ndash2
Bar) greater than the pressure at the
bottom of the stuffing box
Fluid injection is also used to lubri-
cate and cool dry-running packing that
is subject to frictional heat and to pre-
vent air from entering the pump which
reduces flow and operating efficiency
Centrifugal pumps utilize three
types of impellersmdashopen semi-open
and closed (Figures 2 3 amp 4) Open
designs prevent fluids with large solids
from clogging the impellers but at theexpense of pump efficiency Backing
plates on semi-open designs serve to
trap the fluid for more efficient opera-
tion Closed impellers are for use with
clean fluids since solids could ac-
cumulate in the eye which would re-
quire tearing down the pump to remove
them
Single-Stage CentrifugalPumpsSingle-stage centrifugal pumps typi-
cally have good bearing support of the
shaft with few run-out or ldquowhiprdquo prob-
lems However in some cases they
are subject to cavitation This occurs
in the eye of the impeller where the
fluid is under vacuum If the pressure
is low enough it will cause the material
to vaporize forming air or water vapor
bubbles As the fluid passes through
How Pumping Systems Design Affects Sealing Performance
By Chris Boss
8 January 2015
Flow Control Magazine
|
Understanding how different types of pump designs impact
sealing is critical to optimizing efficiency safety and lon-
gevity of the sealing system Used for a wide variety of media
including clear fluids solutions and slurries single-stage
centrifugal pumps are one of the most common
types (Figure 1) Fluid drawn into these pumps
enters the eye of an impeller that spins itto the outside of its container
or volute building pressure as
it moves toward discharge
Some of this fluid will work
its way behind the impeller
where it must be sealed with
compression packing or a
mechanical seal
Figure 1
Figure 2 Figure 3 Figure 4
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3245
the pump under increasing pressure
these bubbles implode sending shock
and vibration through the impeller
adversely affecting the seal This phe-
nomenon can be mitigated by running
the pump at slower speed and higher
pressure at the suction end to prevent
air from entering the fluid
Double-Ended Split-CasePumpsOperating on the same centrifugal prin-
ciple but slightly different geometry are
double-ended split-case pumps (Figure
5) Fluid enters both ends of the pump
and is directed into the eye of an impel-ler which spins it out of the volute to
discharge Packing is installed on both
the shaft and bearing ends so the stuff-
ing box is exposed only to suction pres-
sure which is usually quite low
Axial Flow Pumps Axial flow pumps operate like hydro
turbines in reverse whereby a propeller
(or axial impeller) pushes the fluid to
discharge (Figure 6)
Since the stuffing box is located
downstream of the propeller at the dis-
charge end of the pump the packing is
exposed to the full discharge pressure
Vertical PumpsVertical turbine pumps are typically
flange-mounted on a floor extending
downward into a water-filled sump
hole (Figure 7) Available as single- or
multi-stage pumps they feature an
impeller or series of impellers rotated
simultaneously by a single shaft The
impellers increase the pressure of the
upward flow subjecting the stuffing box
to full discharge pressure
Vertical pumps can be quite long so
inadequate bearing support can cause
the shaft to run out This can induce
undesirable lateral motion on the pack-
ing Worse the packing may be forced
to serve both as a bearing and a seal To
withstand these conditions the packing
should be resilient elastic and resistant
to deformation These properties rule
out packing such as graphite foil in favor
of fiber-based materials
Multi-Stage PumpsMulti-stage pumps are used for high-
pressure applications such as feeding
the boilers in steam-powered generating
plants Stuffing box pressure can vary
with pump design and number of stag-
es Designed for clean fluids and high
operating speeds these pumps typically
have high- and low-pressure ends with ahydraulic pressure equalization line run-
ning between the stuffing boxes
Like vertical pumps multi-stage
pumps feature a series of impellers to
build fluid discharge pressure In the
case of the six-stage pump pictured in
Figure 8 fluid enters at the drive end
where a stuffing box is exposed to suc-
tion pressure Channeled from one
impeller to the next through the pump
casting the fluid can reach extremely
high pressures at discharge
A second stuffing box located at the
bearing end is exposed to an intermedi-
ate pressure from the third impeller This
pressure is greater than the suction pres-
sure but much less than the discharge
pressure which can reach 2000 PSI
Fortunately the stuffing boxes in
these pumps are not exposed to dis-
charge pressures and typically see be-
low 500 PSI which is within the range
of some packing materials
wwwflowcontrolnetworkcom January 2015 29
Figure 5
Figure 6
Figure 7
Figure 8
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 33450 January 2015
Flow Control Magazine
| Gear PumpsPositive-displacement or gear pumps
operate on a different principle than
centrifugal pumps In external gear
pumps the fluid flows around the out-
side of the gears the intermeshing
of which forces it through the pump
to discharge (Figure 9) This design
makes these pumps particularly suit-
able for use with highly viscous fluids
such as resins emulsions syrups and
adhesives As such they are used for
transfer or metering applications
It should be noted gear pumps will
continue to displace fluid as long as
their shafts are turning which can pose
a problem if a clog occurs at the dis-
charge The resulting buildup of pres-
sure can blow out seals and damage
the pump Therefore most gear pumps
have pressure relief valves to divert
fluid back to the suction side for re-
circulation through the pump Internal
gear pumps operate slightly differently
but also have pressure relief valves to
prevent damage from excessive pres-
sure (Figure 10) In both external and
internal gear pumps the maximum
stuffing box pressure is determined by
these valves
Other rotating equipment includes
mixersagitators which are similar to
pumps in terms of the speeds to which
the packing is exposed There are ba-
sically three types of mixersagitators
top- bottom- and side-entry Top-entry
models are subject to the same con-
cerns about shaft run-out ldquowhiprdquo and
lateral forces on the paddles that are
encountered in some vertical pumps
Although some fluid may splash onto
the packing these mixers basically run
dry so the packing must have the abil-
ity to dissipate the resulting frictional
heat
In bottom-entry mixers the packing
is always exposed to fluid and may also
be exposed to solids requiring abra-
sion-resistance If the seal fails the en-
tire contents of the tank will eventually
drain out onto the bearings the floor
and other components under the stuff-
ing box
The packing in side-entry mixers may
be fully or intermittently exposed to flu-
id as well as side loading and vibration
Aside from media temperature
speed and other application variables
the configurations and operating prin-
ciples of rotary-type pumps exert differ-
ent forces on the seals used to keep
them from leaking These forces can
spell the difference between accept-
able seal performance and failure
Understanding these differences has
important implications that should be
taken into account to assure proper
sealing selection for long-term trou-
ble-free performance FC
wwwgarlockcom
Chris Boss is
a senior applica-
tions engineer for
Garlock Sealing
Technologies in
Palmyra NY He
has held various
positions in produc-
tion engineering
product development and applica-
tions engineering for the companyrsquos
compression packing division He
is a BSME graduate of the State
University of New York at Buffalo Mr
Boss can be reached at 800 448-
6688 or chrisbossgarlockcom
Chris Boss
Cavitation | Centrifugal Pump | Pump Packing | Sealing System
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Figure 9
Figure 10
Aside from media temperature speed and
other application variables the configurations
and operating principles of rotary-type
pumps exert different forces on the seals used
to keep them from leaking These forces can
spell the difference between acceptable seal
performance and failure
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3445
NS IDERNDUSTRIAL AUTOMATION + PROCESS CONTROL
WANT
INFORMATION
ON THE
automationindustry
SUBSCRIBE NOW at wwwiainsidercouk
Published by Spitzer and Boyes LLC Write in 15 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3545
Frost says the push from developing
economies is important as the market
is technologically mature and seeing
restricted growth in developed econo-
mies This is particularly true in Europe
and North America where recent finan-
cial insta-
bility has
reduced capital expenditure across end-
user industries
Bill Moore senior vice president of
sales development and channel man-
agement for global bearings manufac-
turer SKF says ldquosmartrdquo products and
the expansion of robust reliability pro-
grams are helping to drive new invest-
ment particularly in developed coun-
tries where the cost to compete is
high Frost says the magnitude of
the existing global installed base will
strengthen the need for replacement
and upgrades adding to market de-
mand as well
Frost says despite the potential
in developing economies the focus
on price as a product differentiator
may lead to intense price pressures
among manufacturers and bring down
the value of the overall market in the
short term The growing trend among
consumers to choose low-cost Chinese
imports will complicate this challenge
As price and quality become stan-
dardized across the globe customers
will base more of their purchasing deci-
sions on value-added services accord-
ing to Frost This will push manufactur-
ers to create more maintenance-free
solutions such as lubrication-free
bearings that offer end-users savings
on service and replacement costs and
reduce downtimeldquoOffering a complete line of prod-
ucts with comprehensive services will
be another feather in the cap of ven-
dors looking to widen their consumer
baserdquo notes Frost Industrial Automa-
tion and Process Control Research
Analyst Guru Mahesh
Moore says the trend of outsourcing
manufacturing to regions where labor
and production costs are favorable is
becoming less of a factor
ldquoThe days when cheap labor made
a significant difference in where a prod-
uct is manufactured mdash particularly high
value-added products or high weight
and bulk products mdash are coming to
an end as the cost of transportation
storage and inventory balance out the
benefits of production costs where la-
bor is a smaller percentage of the cost
of manufacturingrdquo Moore says ldquoLocal
manufacturing development will indeed
come to developing countries as their
ability to create markets that generate
economies of scale that support local
production is a clear trend and one that
all manufacturers will pay attention tordquo
Moore says that development of
maintenance-free or predictive tech-
nologies and products will be a sig-
nificant advantage to everyone in the
Bearing amp Coupling Manufacturers Focus
onDEVELOPING Economies
amp EFFICIENCY InnovationBy Amy W Richardson
2 January 2015
Flow Control Magazine
|
gy
Anew study from Frost amp Sullivan (wwwfrostcom) fore-
casts steady growth for the overall bearings and couplings
market based on rapid industrial development in high-growth
regions Specifically Frost predicts development in Mexico
Indonesia Nigeria Turkey Brazil Russia India and Chinawill help boost the bearings amp couplings market from $2206
billion in 2013 to an estimated $2676 billion in 2018
The development of maintenance-freeor predictive technologies will helpboost growth in the bearings market For example SKF is developing products that will automatically notifyusers when a bearing or mechanicalrotating component is approachingthe end of its useful life Pictured hereis an SKF Microlog analyzer a por- table condition monitoring tool
COURTESY SKF
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
improved productivity through simplified solutions The powerful technology and tools ensure repeatable
reliable accurate measurements Easier access to process data allows for better troubleshooting process
optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
For daily product notes visit the lsquoFeatured Productsrsquo section flowcontrolnetworkcom
ON THE WEB
1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3845
FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
and benefits as well as grids of
instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
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mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
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Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
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1
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FEATURED VIDEO How to Calibrate aPressure Measurement Loop
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7232019 Flow Control January 2015
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THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
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______________________________________________________________________
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One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545
![Page 16: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/16.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1645
The ASCO trademark is registered in the US and other countries The Emerson logo is a trademark and service mark of Emerson Electric Co copy 2014 ASCO Valve Inc
1-800-972-ASCO (2726) | e-mail info-valveascocom | wwwascovalvecomSpoolValve
Now get spool valves with industry-leading ASCO solenoid technology built in
Delivering unmatched performance and durability our compact new valves are
perfect fits for all your onshore near-shore or offshore upstream control panels A
range of easily configured features and options includes superior temperature and
pressure ratings plus low-power models The industryrsquos toughest testing ensures
every rugged stainless steel valve meets or exceeds specifications Plus we design
and support every spool valve we make Ask for ASCO the ultra-reliable choice for oil
and gas control panels
These new spool valves will fit right in
Write in 22 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 174514 | January 2015 Flow Control Magazine
PPLICATIONS CORNER | Process Instrumentation
This is the final article in a series based on the troubleshoot-
ing of a mysterious unit shutdown due to flowmeter perfor-
mance problems
If yoursquove followed this column for most of 2014 you know
that what should have been a liquid ammonia stream to the
feed plant became problematic due to the occurrence of
bubbles of ammonia gas These bubbles caused an ultrasonic
flowmeter in a unit to indicate zero flow and caused the reactor
to scram (shut down) under warm operating conditions The source of the bubbles was traced back to the pres-
sure drop associated with a control valve located at the
exit of the liquid ammonia tank farm
This issue was resolved by identifying the problem
and fixing it at its source This was a pragmatic ap-
proach at the time (early 1980s) given the operation
of the cooling system in the unit and the limited selec-
tion of applicable flowmeter technologies
By the early 1990s changes were implemented that elim-
inated all process cooling requirementsmdashexcept for the small
jacketed cooler upstream of the liquid ammonia flowmeter In
other words after these changes the entire cooling system
would be operated and maintained to cool a few meters of
one small ammonia pipe Coincidently at about the same
time Coriolis mass flowmeters became more mature and
could reasonably measure the mass flow of liquid streams
with homogeneous low levels of vapor
The convergence of these two events resulted in another
approach to the problem that was not available in the early
1980smdashie install a Coriolis flowmeter that could operate in
the presence of bubbles The purchase and installation of a
Coriolis mass flowmeter was given high priority given its im-pact on unit operation economics and safety (by eliminating
the ldquomidget-makerrdquo (see March 2014 page 14))
Plant requirements and the technology that can meet
plant needs keep changing An excellent solution today can
become outdated in just a few years However there are few
substitutes for understanding fundamentals when addressing
a problem In other words there can be more than one way
to skin a cat FC
wwwspitzerandboyescom
Problem Solved AgainA Coriolis mass flowmeter provides a better solution
F o r B e t t e r P i p i ng S y s t e m P e r f o r m a nc e hellipFor Better Piping System Performancehellip
I d e a l f o r Ag g r e s s i v e C h e m i c a l s
1384 POMPTON AVENUE CEDAR GROVE NEW JERSEY 07009
973-256-3000 bull Fax 973-256-4745www p l as t om a t ic co m bull i n f o p la s t om a t ic co m
bull Rugged thermoplasticshandle corrosive andultra-pure chemicaltreatments
bull Constant pressure enhances
pump performancebull Prevents overpressure in
piping system
bull Wide range of pressuresettings
bull PTFE shaft and diaphragm designs
bull 1 4rdquo - 3rdquo sizes in PVC CPVC PVDFPolypro and PTFE
bull First State approved
thermoplastic valve for
anti-siphon applications
Write in 10 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
David W Spitzer
Ammonia Gas | Coriolis Flowmeter | David W Spitzer | Scram | Troubleshooting
FLOWSTREAM Find related content flowcontrolnetworkcom
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and Boyes
LLC offering engineering seminars strategic marketingconsulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer can be reached at 845 623-
1830 or at wwwspitzerandboyescom
The purchase and installation of a
Coriolis mass flowmeter was given
high priority given its impact on unit
operation economics and safetyldquordquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1845
Smart Valve Positioner
Beyond Control The NEW Research Controlreg SRD positioner does
everything you expect any valve positioner to do
plus more The SRDrsquos comprehensive diagnostics tool
continuously monitors for fugitive emissions delivers
real-time performance statistics and facilitates both
proactive and reactive process management Available
with integrated network communications the SRD is
compatible with Research Control valves and most other
pneumatically-actuated valves
Visit wwwbadgermetercomSmart-Valve-Positioners or
call 877-243-1010 for more information today
copy 2015 Badger Meter Inc
RESEARCH CONTROL is a registered trademark of Badger Meter Inc
Write in 11 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1945
Process improvements to increase yield or cut manufactur-
ing costs typically require enhanced process control but the
installed base of measurement instrumentation in a process
plant may simply be unable to facilitate improvements because
of age inadequate performance or unreliability Maintenance
cost and unscheduled process downtime for an aging process
plant can be very damaging to the balance sheet Upgrading
to new more accurate and more reliable instrumentation can
be prohibitively expensive New plant construction must alsomaintain a focus on optimizing costs for the process control
infrastructure The budget approval decision for new plant
construction must weigh such costs against projected market
conditions for the products that the plant is intended to manu-facture In todayrsquos volatile global marketplace return on invest-
ment calculations for plant upgrade or new plant construction
projects may go through several iterations before the trigger is
finally pulled or indeed not pulled
This article describes advances in two-wire instrumenta-
tion specifically in relation to flowmeters that have taken
place in the past few years and the significant cost benefits
that this new technology can realize for plant builders and op-
erators in terms of capital investment and cost of ownership
The Significance of Two-Wire Loop Power
A survey involving 204 participants in the chemical indus-try across Germany Switzerland the UK Canada and the
United States (Manfred Koenig PhD KIM Ludwigshafen
Germany 2006) revealed an 87 percent preference for two-
wire instrumentation versus four-wire in process applications
and 89 percent for utilities This overwhelming preference
may stem from the fact that older process plants were built
with two-wire twisted-pair cable networks connecting all
process units and measuring instruments together in an
overall plant control scheme
However these existing cables are relatively unsophisti-
cated and incapable of supporting anything but low-energy
instrumentation that is insensitive to interference from otherelectrical sources that might be sharing the same cable con-
duit Further the low energy levels supported by these two-
wire loops are more easily rendered safe in terms of explo-
sive risk in hazardous areas containing flammable materials
Many older process plants are also likely to have a significant
installed base of flowmeters employing pre-war (pre-1945)
technology such as positive displacement (PD) turbine vari-
able area (VA or Rotameter) and differential pressure (dP)
Market data firm Flow Research Inc (wwwflowresearch
com) indicates collectively a future compound negative annual
growth rate approaching minus 3 percent to 5 percent for PD
turbine and VA flowmeter types while dP is expected to keeppace with market growth (World Market for Flowmeters 2010)
YSTEMS DESIGN | Flow Measurement
16 | January 2015
Flow Control Magazine
The Two-Wire
ADVANTAGENew wiring options enable modern instrumentsto drive cost savings in existing plant systems
By Steve Milford
Advances in two-wire instrumentation have enabled mod- ern technology to be employed to the advantage of older
plant and process systems
Some chemical manufacturing plants are
competing for survival not only externally
against other global companies but also
internally among the global facilities of theirown company Other industry sectors face
similar challenges
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2045wwwflowcontrolnetworkcom January 2015 | 17
The Need to Replace Older TechnologiesUntil the 21st century two-wire loops were only able
to support these relatively unsophisticated instruments
which convert their measurement by various means into a
4-20mA output or pulse signal to the control system The
more advanced post-war flowmeter technologies such as
Coriolis ultrasonic or electromagnetic flowmeters have
until just eight years ago required a dedicated power sup-
ply for their function in addition to the output loop and
thus a four-wire infrastructure was required as a minimum
Therefore upgrading older two-wire meter devices to moremodern four-wire technology could require significant
expenditure in terms of the installation of separate power
cables and supply modules
There was a major breakthrough in 2006 when a true
two-wire loop-powered inline liquid ultrasonic flowmeter
was introduced (Figure 1) The nature of this breakthrough
was innovation in device power management This was the
missing piece up to that point because to be a true loop-
powered device the meter had to directly provide a full 16
mA span using less than 36 mA of remaining loop current
and less than 1 Watt of electrical energy The flowmeter
operated on a single 4-20 mA HART two-wire loop wasremotely powered by a DC supply was certified Class 1 Divi-
sion 1 and could be deployed as Intrinsically Safe through
the use of an approved safety barrier
A true two-wire loop-powered Coriolis flowmeter followed
in 2011 (Figure 2) employing a new and more advanced
common electronics platform A two-wire loop-powered inline
ultrasonic flowmeter for low-pressure gas was introduced in
2012 and a second two-wire loop-powered Coriolis meter fol-
lowed in 2013 offering improved measurement performance
and an additional high-performance meter tube material
Electromagnetic and vortex flowmeters had already been
available for some years in two-wire loop-powered form butimproved performance resulted as these designs were incor-
COURTESYENDRESS+HAUSER
Figure 1 A two-wire ultrasonic flow- meter released in 2006 operated ona single 4-20 mA two-wire loop
Write in 12 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
omegacom
reg
I I I I LL I
I I I I LL I
copy COPYRIGHT 2015 OMEGA ENGINEERING INC ALL RIGHTS RESERVED
1-888-826-6342
Prices listed are those in effect at the time of publication and are subject to change without noticePlease contact OMEGArsquos sales department for current prices
FPD3000 SeriesStarts at$630
FPD3300 SeriesStarts at
$790
Visit omegacomfpd3000
Visit omegacomfpd3300
OSXL-TIM3$999
Visitomegacomosxl-tim3
Positive Displacement Flow Meterfor Fuels and Oils
bull Aluminum Bodybull FKM Sealsbull Temperatures up to
80ordmC (176ordmF)bull NPT or BSP Threadsbull DIN JIS or ANSI
Connection (Availableon 1 and Larger Sizes)
Positive DisplacementFlow Meter for Solvents
Thermal Imaging CameraFor Inspection andFactory Diagnosis
Note Not for ExportUSA Only
Your One-StopSource for Process
Measurement and Control
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 214518 | January 2015
Flow Control Magazine
porated into their new common electron-
ics platform in 2013 So all the ldquomodernrdquo
flow measurement technologies mdash that
is to say those introduced post-war mdash
have become available as two-wire loop-
powered devices with one exception
namely thermal mass (thermal disper-
sion) meters Unfortunately the power
requirements for this technology exceed
what is currently deemed possible withtwo-wire loop-power management
Payback forTechnology UpgradeConsider a 1rdquo process line
containing a liquid process
ingredient costing $1lb at a
mass flowrate of 150 lbmin-
ute We have $150minute
flowing in the line translating
to $9000hour and $72000
per eight-hour shift That cal-culates further to $360000
per five-day working week and
for a working year of 40 weeks for
example that is $144 million Assume
the existing device is a turbine flowmeter
Now imagine a two-wire loop-
powered Coriolis mass flowmeter is
installed in place of the existing meter
The line would need to be drained and
probably one process flange replaced
allowing the Coriolis to fit mechanically
in place of the turbine However thetwo-wire loop already used for carrying
the existing meterrsquos flow signal to the
control room can be used unaltered
for the complete electrical installation
aspects of the Coriolis flowmeter
The upside of the change is signifi-
cant and clear cut Assuming the exist-
ing meter measurement uncertainty was02 percent of reading then measure-
ment uncertainty improves through use
of Coriolis to 01 percent of reading
giving a 01100 x $14400000 im-
provement in control of the ingredient
annually or $14400 A two-wire Coriolis
mass flowmeter with 01 percent mass
flow accuracy would be paid for in ap-
proximately 6-8 months In practice the
improvement in measurement uncer-
tainty would be greater as the operator
would gain temperature and density in-formation from the Coriolis and the mea-
surement would be devoid of any fluid
property dependence Viscosity change
for example can have a major impact on
turbine meter performance Mechanical
wear and tear that turbine meters even-
tually experience which causes them to
under-register flow is precluded by mod-
ern devices like Coriolis
Furthermore if the process ingredient
was being blended with another then ad-
ditional process improvements could berealized through in-line blending control
using Coriolis technology for final density
as the control point It is possible to have
dual 4-20 mA outputs from two-wire
loop-powered meters but as the main
4-20 mA output representing the prima-
ry variable is also HART then an external
HART Loop Converter or HART IO card in
the control system can provide second-
ary tertiary and quaternary variables as
4-20 mA signals A Coriolis meter is trulya multi-variable device Certain two-wire
devices are also available with Profibus
or Foundation Fieldbus communication
Cutting Wiring CostsIn 2003 WIBEXERA (International
Instrument Usersrsquo Associations) Report
T 2732 X 03 was published and it pro- vided an average survey of prices quoted
in projects at that time for the provision
of power supplies for four-wire instru-
ments The price ranged from euro1200
to euro1800 per instrument depending
upon design and plant characteristics
for an average cost of euro1500 (about
$2000) It would be reasonable to
assume an inflationary factor of 2 per-
cent per annum giving an approximate
current-day figure of $2500
From another source within thechemical industry an estimation of
$40foot to $50foot was given for in-
stallation of four-wire cabling For a
linear 50-foot cable run with for ex-
ample a 10-foot vertical at each end
this equates to $3150 Actual costs
and budget estimates have been given
as high as $10000
The Extent of the Opportunity The modern post-war flow measure-
ment technologies have different powerrequirements and consequently they
are not all available for the
same size range in two-wire
loop-power form For example
two-wire Coriolis flowmeters
are limited to 2rdquo diameter
electromagnetic and inline
low-pressure gas ultrasonics
are limited to 8rdquo and vortex
and inline liquid ultrasonic are
limited to 12rdquo
Nevertheless for thechemical industry in particu-
lar perhaps two-thirds of the
process pipes in a plant will be no larger
than 2rdquo and even when the host process
pipe is larger a correctly sized flowmeter
can still be less than 2rdquo There is consid-
erable scope for two-wire loop-power to
deliver value for flow measurement ap-
plications with total safety
The virtues of Coriolis technology
have been covered but what about
other two-wire technologies An elec-tromagnetic flowmeter in two-wire form
YSTEMS DESIGN | Flow Measurement
In todayrsquos volatile global mar-
ketplace return on investment
calculations for plant upgrade or
new plant construction projects
may go through several itera-
tions before the trigger is finally
pulled or indeed not pulled
ldquo
rdquo
COURTESYENDRESS+HAUSER
Figure 2 Two-wire Coriolis flowme- ters became available in 2011
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2245
can be used on water wastewater or
a light water-based slurry provided the
fluid has around a 20 microSeimenscenti-
metre (microScm) electrical conductivity
A magnetic flowmeter is full bore un-
less flowrates dictate a reduced meter
size in the interests of performance and
so there are no intrusions into the flow
stream and no pressure loss An accu-
racy of 05 percent of reading is normal
from a two-wire magnetic meter and a
modest five diameters (5D) of straight in-let run is needed to avoid error from up-
stream flow disturbances When the fluid
exhibits insufficient conductivity then
the same performance and installation
requirements can be met by an inline ul-
trasonic flowmeter provided the liquid is
essentially clean and bubble-free
For gas or steam applications a vor-
tex meter is the normal choice Using a
built-in temperature sensor a two-wire
loop-powered vortex meter can calculate
mass flow of saturated steam using in-ternal steam tables An external pressure
input allows mass flow of steam to be ac-
curately calculated even when saturated
steam becomes superheated as can oc-
cur downstream of a pressure regulating
valve With mass flow known the vortex
meter can calculate energy and heat flow
A new and exciting development is
the ability of the vortex meter to indicate
wet steam and calculate dryness frac-
tion or steam quality For safety and ef-
ficiency saturated steam should be dry
and free from condensate that is to say
it should possess a high steam quality
factor However the dry or wet state of
saturated steam can sit on a knife-edge
and shift to the opposing state due to
the slightest change in process condi-
tions Rapid and reliable indication of
this change of state is now available
Perhaps the most astonishingachievement in the power management
of two-wire loop-power flowmeters is
that of the ultrasonic biogas meter It is
now possible not only to measure the
flow of wet dirty variable composition
and low-pressure anaerobic digester
gas landfill gas and coal bed methane
gas with a two-wire loop-powered ultra-
sonic flowmeter but also the same de-
vice uses an inbuilt temperature sensor
in combination with measured sound
velocity to calculate methane contentcalorific value and energy flow
Technology to Take UsForwardModern flow technologies provide instru-
ment engineers with vital self-monitoring
information The format of such infor-
mation is easier to understand and act
upon when presented in accordance
with harmonized international guidelines
for online plant asset management eg
NAMUR Standard 107
Continuous plain-text self-diagnostic
and process-related information with
suggested remedies (Figure 3) make it
possible for instrument engineers andoperators to take action at the appro-
priate time mdash immediately or during
the next scheduled shutdown mdash saving
time and money by knowing the exact
health of their measuring point and the
probable actions required to rectify any
abnormal conditions Device verifica-
tion offering third-party validated trace-
ability can be performed on demand ei-
ther locally or remotely from the control
room without the expense of a man in
the field Calibration is then avoided ordeferred without process interruption
Where a process plant has a large
installed base of older mechanical tech-
nologies the decision to embark upon a
program of replacement for plant mod-
ernization cannot of course be taken
easily There are the stocks of spare
parts to consider along with the plant
instrument technicians who are trained
on and at ease with the old devices
However a process plant that retains
the older technology going forward willbe at risk and may find it increasingly
difficult or even impossible to maintain
a cost position that competes effective-
ly in the global market FC
wwwusendresscom
wwwflowcontrolnetworkcom January 2015 | 19
Steve Milford
is a Flow Product
Business Manager
for Endress+Hauser
Inc in Greenwood
Ind He has been
involved in flow
measurement since
1983 and has been
actively involved with standards devel-
opment for flow technology within the
International Standards Organization
(ISO) and the British Standards
Institute Mr Milford can be reached
at stevemilfordusendresscom
Steve Milford
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Coriolis Flowmeter | Magnetic Flowmeter | Two-Wire | Ultrasonic Flowmeter | Vortex Flowmeter
Figure 3 A modern instrumentrsquos display module can provide continuous plain- text self-diagnostic and process-related information
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2345
The bottom line is the volume of gas under one set of
pressure and temperature conditions is not the same as it
would be for the gas under different conditions Why is thisimportant Without compensation for compressibility read-
ings taken by gas flowmeters can result in measurementsmdash
and costs to the buyermdashsignificantly lower or higher than they
should be
The flow of gas in a system can be accounted for and
reported in a number of ways such as by volume by mass
flowrate and by energy Inline turbine meters can offer both
reliability and accuracy in measuring gas flow when matched
with a monitor capable of calculating and displaying results
that have been adjusted for the nature of the gas and impor-
tantly the pressure and temperature
Measuring Flow with an Inline TurbineFlowmeter
With an inline turbine meter gas flows into the meter through
a length of piping that helps to pre-condition the flow by
reducing undesirable swirls and asymmetry Where consid-
ered necessary a flow straightener may even be installed in
line to create a uniform flow profile to the extent possible
As can be seen in Figure 1 a rotor support within the tur-
bine housing further conditions the flow and directs it through
the blades of the rotor High-precision ball bearings allow the
rotor to freely rotate on the shaft
The rotorrsquos rotational speed is directly proportional to the velocity of the fluid passing through the meter The rotor itself
incorporates magnets (or magnetic blades depending on thedesign) while the housing is non-magnetic
A proximity sensor (also known as a pickup coil) is located
in line with the rotor and detects the electrical pulses gener-
ated by the ferrous rotor spinning through the magnetic field
Each pulse represents a discrete volume of gas The out-
put frequency provides the indication of the gas flow rate and
the accumulated pulses over a specified time represent the
total volume of fluid for that measurement period
Need for Calibration The flowrate of the gas through the meter cannot be deter-
mined accurately unless the meter is calibrated The fac-tory calibration determines the meterrsquos constant known
as a K-factor which is then inputted into the gas monitor
PPLICATION NOTES | Flow Measurement
20 | January 2015
Flow Control Magazine
COMPENSATING for
Compressibility inMeasuring Gas Flow Why K-factor adjustment is essential foraccurate inline turbine flow measurement
Unlike crude oil and other liquid fossilfuels natural gas poses a challenge
in monitoring the quantity of gas flowing
through pipelines While liquids do not com-
press gases do and the mass flowrate of
gas being transmitted through gathering
lines depends on both the pressure and
temperature
By Kevin Clark
Figure 1 Internal components of a liquid turbine flowmeter
C O U R T E S Y
T U R B I N E S
I N C
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2445
Wondering Whether the
Pump Guy Seminar
Is for YouCheck out the ldquoPump Guy Insightsrdquo
video series flwctrlcompginsights
PUMP GUY INSIGHT 1NPSHa vs NPSHrmdashWhy all pumps need gauges
PUMP GUY INSIGHT 3How to Operate Your Pump at Best Efficiency
PUMP GUY INSIGHT 5Head vs Flow
PUMP GUY INSIGHT 2 Your Pumps Are Constantly Moving On Their Curves
PUMP GUY INSIGHT 4 The Role of the Pump Reliability Chain
PUMP GUY INSIGHT 6How to Read a Pump Curve
PARTNER SPONSORSFor more information and to register
for upcoming Pump Guy Seminars
visit FlowControlNetworkcomPumpGuy
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2545
PPLICATION NOTES | Flow Measurement
22 | January 2015
Flow Control Magazine
Gas flowmeters measure the actual volume of gas passing
through the meter per minute irrespective of pressure and
temperature1
The volumetric flowrate of a gas is often corrected to
ldquostandardizedrdquo conditions of pressure and temperature While
ldquostandardrdquo conditions can vary depending on the definition
in the US this typically means a pressure of 1473 PSIA(pounds per square inch absolute) and a temperature of 60 F
The flowrate measurement is reported in standard cubic feet
per minute (SCFM)
Compensating for changes in pressure and temperature is
critical Consider a meter system setup for flowing conditions
of 60 PSIG (pounds per square inch gauge) and 60 F and the
line pressure decreases to 50 PSIG while the temperature
remains constant The difference in SCFM between the two
is more than 15 percent which would cost the buyer more
for the gas than it should As Table 1 demonstrates even a
small variation in pressure will result in a surprisingly high er-
ror percentage
Automation of the K-Factor The K-factor is established by an initial factory calibration In
the case of a non-compensated flow monitor any variations
in pressure and temperature will result in manual adjust-
ments needed to the K-factor In order to maintain accurate
flow measurement users must monitor pressure and temper-
ature and make corresponding adjustments to the K-factor To eliminate these manual adjustments some suppliers offer
a flow monitor that automatically adjusts for any changes in
pressure and temperature
These monitors provide accurate flow measurement regard-
less of changing environmental conditions in some cases sup-
porting applications with pressures as high as 15000 PSIG and
temperatures between -350 F to 350 F with a standard accura-
cy of +-1 percent over a flow range of 05 ACFM to 650 ACFM
Final NotesDuring the operation of a flowmeter system the ability to obtain
a readout mdash and to adjust for line pressure and temperaturechanges mdash is sometimes compromised by a lack of electric
power This issue is especially true along gas pipelines in remote
areas To overcome this limitation some manufacturers have
designed low-powered flow monitors which can operate for up
to on year on a single lithium D-cell battery
It is important for users to recognize the effects of the
compressibility of gas As such the quantity of a gas flow-
ing through a gas flowmeter depends on the pressure and
temperature In order to ensure accuracy any flowmetering
system must employ a means to correct for these effects
Otherwise the readout is certain to be in error and could be
unnecessarily costing money This is particularly crucial onwellhead production and in billing scenarios FC
wwwturbinesincorporatedcom
Notations1 The measurement factor in the US is known as the
ACFM actual cubic feet per minute (Metric units are typically
ACMH actual cubic meters per hour)
Table 1 Error induced by line pressure changes
Constant Temperature with Varying Pressure
Pressure Temperature PulsesSCF Error
50 60 2556027821 1546
51 60 2517123288 1370
52 60 2479385307 1199
53 60 2442762186 1034
54 60 240720524 873
55 60 237266858 717
56 60 2339108911 566
57 60 2306485356 418
58 60 2274759285 275
59 60 2243894166 136
60 60 2213855422 000
61 60 2184610304 132
62 60 2156127771 261
63 60 2128378378 386
64 60 210133418 508
65 60 2074968632 627
66 60 2049256506 743
67 60 2024173807 857
68 60 1999697703 967
69 60 1975806452 1075
70 60 1952479339 1181 Flow Measurement | K-Factor | Measurement
Accuracy | Turbine Flowmeter
Find related content flowcontrolnetworkcomhellipSearch on
FLOWSTREAM
Kevin Clark is senior develop-
ment engineer for Turbines Research
amp Development LLC Turbine RampD is a
subsidiary and the research and techni-
cal support arm of Turbines Inc which
serves a range of industries and applica-
tions from oil amp gas to cryogenic liquids
to custody transferKevin Clark
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2645
Pumps Bearings amp Seals TECHNOLOGY REPORT
FEATURES
SYSTEMS DESIGN
The ComplicatedCase of
Compressors
withSide-Streams
24 28 32BEST PRACTICES
How PumpingSystems
AffectSealing
Performance
TECH OUTLOOK
BearingSuppliers
Drive Gains InDeveloping
Markets
wwwflowcontrolnetworkcom January 2015 | 23
S P E C I AL S E C T I O N
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2745
The design and operation of compressors with side-
streams has always been difficult because flow entering the
compressor needs to be mixed with the core flow already
in the compressor (compressed in section-1) in a manner
that does not degrade the aerodynamic performance of sur-
rounding sections Minimizing losses and ensuring proper
mixing of the side-stream flow and core-flow are required to
ensure effective performance of a compressor of this sort
Key considerations for an application involving compres-
sors with side-stream flow include
The plant process typically dictates the side-stream
flange pressure
The impellers upstream of the side-stream should
achieve the necessary pressure for the core-flow
The side-stream flow is typically at a temperature dif-
ferent from compressor core-flow temperature
Process plants need some degree of operational flex-
ibility ie the ability to support variations in core-flow condi-
tions and side-stream conditions
Modern process plants are usually specifying more than
one operating conditions (sometimes two or more manda-
tory conditions) which can present challenges to compres-
sors with side-streams Adding to these issues modern
compressors should operate with much higher impeller tip
The COMPLICATED CASE ofCompressors with Side-StreamsConsidering key system design requirements
to ensure operational efficiency By Amin Almasi
4 January 2015
Flow Control Magazine
|
y
g
Some compressors in certain applications
have one or more incoming side-streams
(or side-loads) that introduce side-stream
flow to mix with the core flow In other words
a radial side-stream inlet is utilized in multi-
impeller centrifugal compressors to introduce
additional gas into the mid-stage of a com-
pressor This design enables optimization in
some process plants However the flow dis-
tribution after the junction of the side-stream
and the main return channel of the upstream
section can significantly affect the perfor-mance of the next section of compressor
In most cases the pressure levels at these
side-streams should be accurately predicted
to meet the theoretical performance
Compressor station at a natural gas processing plant
R U D M E R Z W E R V E R I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2845
speeds and inlet Mach numbers compared to previous
generations of compressor technology
Likewise side-streams are now com-
monly used with medium-sized and
large-sized compressors (eg 1ndash60
MW) The costs associated with cor-
rections on side-stream compres-
sor applicationsmdashany repair
inefficient operation and power
lossesmdashwould be very high Fur-
ther compressors with side-streams
are usually sensitive and difficult
machines to operate In particular
performance curves (performance
pressures efficiency etc) are sen-
sitive to suction inlet conditionsside-stream inlet conditions vol-
ume flow ratio (side-stream vol-
ume to core-flow volume) and side-stream losses
Compressors with side-stream often perform far below
expectations The main reason is that side-stream compres-
sors are different than conventional compressors (without
a side-stream) in design and operation For a compressor
with side-streams tighter tolerances in operating conditions
must be identified and applied Uncontrolled variations of
suction pressure or side-stream pressure are major prob-
lems Another major issue is the variations of the flow ratio
(side-stream flow to core-flow)
Compressor Side-Stream amp Mixing SectionIn many centrifugal compressors the portion of the side-
stream system from the flange connection to the mixing
section is similar to a compressor inlet A great challenge
is ensuring the mixing section provides circumferentially
uniform merged-flow with minimum losses This can be
achieved via effective design of the inlet configuration and
mixing section of the side-stream compressor such that
the impeller can be maintained over the whole operating
range of the compressor In many cases while there are
mixing sections provided for the machine the flows do not
completely mix before entering the impeller of the section-2
(the impeller after the mixing section) Non-uniformity at
inlet flow to the impeller is a key concern for compressor
performance
Another consideration is a compact design of the side-
stream mixing section Specifically a mixing section with
less axial length is always preferred This axial length can af-
fect the compressor rotor dynam-
ics the rotor length and over-
all compressor performance
(design cost operation and
reliability)
The side-stream exit pressure
(side-stream pressure at inlet
of the mixing section) is mainly
a function of the side-stream
flow velocity and the pres-
sure in the previous section of
the compressor Conversely the side-
stream flange pressure can depend on
side-stream flow velocity and section-1
exit conditions Therefore the side-stream
inlet flange volume flow is a function of theflange pressure compressibility (at that
pressure and temperature) and mass flow
Some engineers assume that the side-stream flange pres-
sure is equal to the inlet pressure of the first impeller of the
section-2 This is not true The mixed total pressure can be
estimated on a mass-averaged basis using side-stream total
pressure and return channel exit (section-1) total pressure
In some designs because of the lower static pressure at
the side-stream exit the total pressure at the return channel
exit is lower even though the velocity upstream is roughly
matched for both streams The pressure usually increased
at the returned channel but it can be reduced again at the
side-stream exit While simple in nature this can have an
impact on the prediction of pressure at the side-stream exit
and overall mixing section performance Based on basic flow
principles it was usually assumed that the static pressure
was equal between both flow streams at the mixing location
While this assumption might be used in rough calculations
the accurate simulations have shown this assumption is not
true In fact there are some points (for instance the shroud
wall at the exit of the return channel and the hub wall at
the exit of the side-stream) where this assumption is true
However this is not valid for all locations There are pressure
changes that occur from a side-stream flange to the inlet
of the next section (section-2) which depend on different
factors The first factor is the frictional losses due to side-
stream geometry from side-stream flange to plenum mix-
ing section etc The other factors are pressure changes due
to local curvature and geometry details of mixing section
Another consideration is the operation of a compressor
with side-stream at part-load The performance of the side-
wwwflowcontrolnetworkcom January 2015 25
Figure 1 An example of a centrifugalcompressor with side-stream
COURTESY SIEMENS
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 29456 January 2015
Flow Control Magazine
|
y
g
stream path the mixing section and
the downstream impellers when ma-
chine is operated at part-load or even
off-design operating flows will result
in additional compressor performance
problems In such a case both veloc-
ity profiles and pressure variations in
various parts (side-stream path mixing
section etc) will be different resulting
in complicated flow patterns and com-
plex aerodynamics behaviors
Side-Stream CompressorSectional Performance
Typically vendor-supplied compressor
performance curves reflect flange-to-flange performance because that is
what the plant engineers need to
evaluate the proper operation of their
system (for example from suction to
side-stream and from side-stream to
discharge) In many cases compres-
sor vendors also provide the over-
all compressor performance curves
and performance curves for section-1
(from suction to side-stream) and sec-
tion-2 (from side-stream to discharge)
Flange-to-flange data if not interpret-
ed properly can lead to false conclu-
sions about the relative performance
of individual sections of a compression
system For example if side-stream
losses from the flange to mixing sec-
tion are attributed to the downstream
section (section-2) it will cause the
downstream section (section-2) to
appear low in performance while the
upstream section (section-1) will show
high performance levels
An important behavior to con-
sider is when the actual side-stream
pressure is different than the rated
side-stream pressure When the side-
stream pressure is slightly higher than
the outlet pressure of the section-1
it (section-1) shows a relatively higher
performance compared to the real sec-
tion-1 performance In some cases
the performance of section-1 could be
considerably higher than section-2 In
other words when performance is de-
termined flange to flange the higher
flange pressure is seen as extra ldquopseu-
dordquo work done by the section (since this
is an inconsistent thermodynamic vol-
ume) resulting in a relatively high sec-
tional efficiency (section-1 shows a rel-
atively high efficiency) This is the case
for many compressors with side-stream
because the whole system is designed
(or specifically the side-stream location
is selected) in a way aimed at main-
taining the real side-stream pressure(side-stream inlet) above the section-1
outlet pressure because if the real side-
stream pressure becomes lower than
the section-1 outlet pressure the flow
may (theoretically) reverse
This is particularly important when
the side-stream mass flow is much
lower than the mass flow of core-flow
The above-mentioned reasons explain
why in many simulations calcula-
tions and performance reports related
to compressors with side-stream the
section-1 shows a relatively good ef-
ficiency and section-2 appears low in
efficiency
When the side-stream pressure is
slightly lower than the outlet pressure
of the section-1 the section-1 might
show a relatively lower performance
compared to section-2 This could oc-
cur in some recycle services where the
side-stream is actually a recycle flow
with a mass flow around two to five
times the core-flow The side-stream
(recycle) flow is returned from down-
stream of the compressor to be slightly
compressed and recycled to the down-
stream Such a recycled side-stream
compressor can present unique chal-
lenges for design and operation This
kind of machine usually needs very
special operating procedures and very
fine adjustments regarding operating
pressures and flows
Side-Stream Compressor
Performance amp Operation An important consideration is the sen-
sitivity of compressor overall perfor-
mance curve and sectional perfor-
mance curves to the flow ratio (ratio
of side-stream flow to core-flow) and
to the inlet conditions Variations in
the flow and pressure of the main
suction and side-stream inlet should
be controlled within tight tolerances
For compressors with side-stream the ASME PTC-10 code stipulates limits on
flow ratio (side-stream volume to core-
flow volume) The acceptable variation
in volume flow ratio in a compressor
with a side-stream is +-5 percent as
per ASME PTC code The requested
side-stream pressure tolerance is not
usually specified in compressor codes
but it should be around +- 2 percent
(or sometimes +- 25 percent)
Variance in flow ratio impacts the
velocity levels where the two streams
merge Significant variation in the ve-
locity profile upstream of the impeller
changes the incidence on the blade
leading edge of the following impel-
ler This change in incidence leads to a
change in sectional performance over-
all compressor performance and train
efficiency
If the flow ratio is varied between 95
percent and 105 percent (tolerances
specified in the ASME PTC-10 code)
the flange pressure changes accord-
ingly resulting in a change in the sec-
tional performance and overall perfor-
mance The sectional efficiency varies
sometimes more than +- 4 percent
This variance reduces as the flow is de-
creased toward surge However as the
flow is increased toward overload the
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3045wwwflowcontrolnetworkcom January 2015 27
variance increases up to higher values
(even in some cases three to five times
compared to variations near the surge
zone) For example in a case study
for a compressor with side-streams a
+- 5 percent variation in flow ratio and
associated changes (pressures losses
etc) the sectional efficiency reduced by
approximately 34 percent at the rated
flow at allowable operating points at
the end of curve (near the overload
ie choke) efficiency reduced by ap-
proximately 55 percent These results
show that the variation in sectional
performance and overall performance
due to flow ratio is highest at operat-ing points near the overload and low-
est at operating points near the surge
For compressors which work most of
the time at high flow (flow higher than
rated flow and discharge pressure low-
er than rated pressure) the effects of
flow ratio deviations (and subsequently
efficiency reduction) would be higher
than compressors working on the left-
hand side of curve (say with sufficient
margins near the surge)
In the compressor codes (such as
API 617) the compressor power varia-
tions should be maintained below 4
percent However in some applica-
tions clients require tighter tolerances
on the consumed power sometimes
below 2 percent (or even below 15
percent) Some studies suggest while
+- 5 percent of volume flow ratio is
suitable for performance test as per
ASME PTC-10 code some plants re-
quire tighter control on the consumed
power and compressor performance
(lower limits on the efficiency) the tol-
erances on the volume flow ratio could
be tighter than ASME PTC code In this
regard +- 4 percent tolerance can be
suggested on the volume flow ratio (ra-
tio of side-stream flow to core-flow) of
compressors with side-streams
Based on operational experiences
acceptable variations in volume flow
ratio and inlet pressures (suction inlet
and side-stream inlet) of a compressor
with side-streams are +- 4 percent
and +- 2 percent respectively
Another important consideration is
the required adjustments for the flow
ratio (side-stream flow to core-flow)
Compressors with side-stream usually
require fixed side-stream flange pres-
sures For a compressor with some variations in operation conditions (even
small changes) it is not usually pos-
sible to achieve optimum operation by
keeping the flow ratio (side-stream to
core-flow) constant The flow ratio has
to be adjusted according to the inlet
flow at which the machine is operating
in order to get the required correspond-
ing side-stream flange pressure
Thermal changes have also been
known to cause some instability in
centrifugal compressors An example is
the thermal-induced change of resid-
ual unbalance For compressors with
side-streams which feature tempera-
ture differences between core-flow and
side-stream flow the thermal behav-
ior of the compressor is usually more
complex and requires more attention
Heavy Gas ChallengeHeavy gases (such as heavy hydrocar-
bon gases eg propane propylene
MTBE (Methyl Tertiary Butyl Ether))
have very low gas sonic velocities that
produce high Mach numbers in the
aerodynamic flow paths For these
services because of high Mach num-
ber high flow coefficient stages have
very narrow flow maps characterized
by limited surge and choke margins
Compressors with side-streams in
these services present great challeng-
es This is to say the side-streams and
associated mixing further complicate
design operation and performance
prediction because the pressure tem-
perature and flow conditions at each
one of these side-streams as well
as at the exit of the machine require
stringent tolerances to optimize the
overall efficiency and performance
As such it is important to accuratelymodel design operate and moni-
tor performance characteristics of any
impellers diffusers return channels
and generally all flow-path components
in a compressor with side-stream FC
Amin Almasi
is a senior rotating
machine consultant
in Australia He is
a chartered profes- sional engineer of
Engineers Australia
(MIEAust CPEng ndash
Mechanical) and
IMechE (CEng MIMechE) holds
bachelorrsquos and masterrsquos degrees
in Mechanical Engineering and is
a registered professional engineer
in Queensland He specializes in
rotating machines including cen-
trifugal screw and reciprocating
compressors gas turbines steamturbines engines pumps subsea
offshore rotating machines LNG
units condition monitoring and reli-
ability Mr Almasi is an active mem-
ber of Engineers Australia IMechE
ASME and SPE He can be reached
at aminalmasiymailcom
Amin Almasi
Compressor | Gas Flow | Performance Curve | Side-Stream Flow
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3145
The pressure in the stuffing box
containing the packing can be estimat-
ed by the following equation
SBP = [Discharge ndash Suction] 3 + Suction
Pressure at the bottom of the stuff-
ing box will be higher than the suction
pressure but considerably lower than
the discharge pressure It should be
noted this calculation will yield a con-
servative estimate of stuffing box pres-
sure that can be further reduced by
pump design
A hole in the stuffing box serves as
a port for injecting clean fluid that cir-
culates around a lantern ring aligned
under the flush port The fluid flushes
solids back into the process to protect
the packing from abrasive wear If the
clean fluid is injected at a pressure ex-
ceeding that at the bottom of the stuff-
ing box some of it will leak back into
the process and some will leak out to
the atmosphere Recommended flush
injection pressure is 15ndash30 PSI (1ndash2
Bar) greater than the pressure at the
bottom of the stuffing box
Fluid injection is also used to lubri-
cate and cool dry-running packing that
is subject to frictional heat and to pre-
vent air from entering the pump which
reduces flow and operating efficiency
Centrifugal pumps utilize three
types of impellersmdashopen semi-open
and closed (Figures 2 3 amp 4) Open
designs prevent fluids with large solids
from clogging the impellers but at theexpense of pump efficiency Backing
plates on semi-open designs serve to
trap the fluid for more efficient opera-
tion Closed impellers are for use with
clean fluids since solids could ac-
cumulate in the eye which would re-
quire tearing down the pump to remove
them
Single-Stage CentrifugalPumpsSingle-stage centrifugal pumps typi-
cally have good bearing support of the
shaft with few run-out or ldquowhiprdquo prob-
lems However in some cases they
are subject to cavitation This occurs
in the eye of the impeller where the
fluid is under vacuum If the pressure
is low enough it will cause the material
to vaporize forming air or water vapor
bubbles As the fluid passes through
How Pumping Systems Design Affects Sealing Performance
By Chris Boss
8 January 2015
Flow Control Magazine
|
Understanding how different types of pump designs impact
sealing is critical to optimizing efficiency safety and lon-
gevity of the sealing system Used for a wide variety of media
including clear fluids solutions and slurries single-stage
centrifugal pumps are one of the most common
types (Figure 1) Fluid drawn into these pumps
enters the eye of an impeller that spins itto the outside of its container
or volute building pressure as
it moves toward discharge
Some of this fluid will work
its way behind the impeller
where it must be sealed with
compression packing or a
mechanical seal
Figure 1
Figure 2 Figure 3 Figure 4
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3245
the pump under increasing pressure
these bubbles implode sending shock
and vibration through the impeller
adversely affecting the seal This phe-
nomenon can be mitigated by running
the pump at slower speed and higher
pressure at the suction end to prevent
air from entering the fluid
Double-Ended Split-CasePumpsOperating on the same centrifugal prin-
ciple but slightly different geometry are
double-ended split-case pumps (Figure
5) Fluid enters both ends of the pump
and is directed into the eye of an impel-ler which spins it out of the volute to
discharge Packing is installed on both
the shaft and bearing ends so the stuff-
ing box is exposed only to suction pres-
sure which is usually quite low
Axial Flow Pumps Axial flow pumps operate like hydro
turbines in reverse whereby a propeller
(or axial impeller) pushes the fluid to
discharge (Figure 6)
Since the stuffing box is located
downstream of the propeller at the dis-
charge end of the pump the packing is
exposed to the full discharge pressure
Vertical PumpsVertical turbine pumps are typically
flange-mounted on a floor extending
downward into a water-filled sump
hole (Figure 7) Available as single- or
multi-stage pumps they feature an
impeller or series of impellers rotated
simultaneously by a single shaft The
impellers increase the pressure of the
upward flow subjecting the stuffing box
to full discharge pressure
Vertical pumps can be quite long so
inadequate bearing support can cause
the shaft to run out This can induce
undesirable lateral motion on the pack-
ing Worse the packing may be forced
to serve both as a bearing and a seal To
withstand these conditions the packing
should be resilient elastic and resistant
to deformation These properties rule
out packing such as graphite foil in favor
of fiber-based materials
Multi-Stage PumpsMulti-stage pumps are used for high-
pressure applications such as feeding
the boilers in steam-powered generating
plants Stuffing box pressure can vary
with pump design and number of stag-
es Designed for clean fluids and high
operating speeds these pumps typically
have high- and low-pressure ends with ahydraulic pressure equalization line run-
ning between the stuffing boxes
Like vertical pumps multi-stage
pumps feature a series of impellers to
build fluid discharge pressure In the
case of the six-stage pump pictured in
Figure 8 fluid enters at the drive end
where a stuffing box is exposed to suc-
tion pressure Channeled from one
impeller to the next through the pump
casting the fluid can reach extremely
high pressures at discharge
A second stuffing box located at the
bearing end is exposed to an intermedi-
ate pressure from the third impeller This
pressure is greater than the suction pres-
sure but much less than the discharge
pressure which can reach 2000 PSI
Fortunately the stuffing boxes in
these pumps are not exposed to dis-
charge pressures and typically see be-
low 500 PSI which is within the range
of some packing materials
wwwflowcontrolnetworkcom January 2015 29
Figure 5
Figure 6
Figure 7
Figure 8
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 33450 January 2015
Flow Control Magazine
| Gear PumpsPositive-displacement or gear pumps
operate on a different principle than
centrifugal pumps In external gear
pumps the fluid flows around the out-
side of the gears the intermeshing
of which forces it through the pump
to discharge (Figure 9) This design
makes these pumps particularly suit-
able for use with highly viscous fluids
such as resins emulsions syrups and
adhesives As such they are used for
transfer or metering applications
It should be noted gear pumps will
continue to displace fluid as long as
their shafts are turning which can pose
a problem if a clog occurs at the dis-
charge The resulting buildup of pres-
sure can blow out seals and damage
the pump Therefore most gear pumps
have pressure relief valves to divert
fluid back to the suction side for re-
circulation through the pump Internal
gear pumps operate slightly differently
but also have pressure relief valves to
prevent damage from excessive pres-
sure (Figure 10) In both external and
internal gear pumps the maximum
stuffing box pressure is determined by
these valves
Other rotating equipment includes
mixersagitators which are similar to
pumps in terms of the speeds to which
the packing is exposed There are ba-
sically three types of mixersagitators
top- bottom- and side-entry Top-entry
models are subject to the same con-
cerns about shaft run-out ldquowhiprdquo and
lateral forces on the paddles that are
encountered in some vertical pumps
Although some fluid may splash onto
the packing these mixers basically run
dry so the packing must have the abil-
ity to dissipate the resulting frictional
heat
In bottom-entry mixers the packing
is always exposed to fluid and may also
be exposed to solids requiring abra-
sion-resistance If the seal fails the en-
tire contents of the tank will eventually
drain out onto the bearings the floor
and other components under the stuff-
ing box
The packing in side-entry mixers may
be fully or intermittently exposed to flu-
id as well as side loading and vibration
Aside from media temperature
speed and other application variables
the configurations and operating prin-
ciples of rotary-type pumps exert differ-
ent forces on the seals used to keep
them from leaking These forces can
spell the difference between accept-
able seal performance and failure
Understanding these differences has
important implications that should be
taken into account to assure proper
sealing selection for long-term trou-
ble-free performance FC
wwwgarlockcom
Chris Boss is
a senior applica-
tions engineer for
Garlock Sealing
Technologies in
Palmyra NY He
has held various
positions in produc-
tion engineering
product development and applica-
tions engineering for the companyrsquos
compression packing division He
is a BSME graduate of the State
University of New York at Buffalo Mr
Boss can be reached at 800 448-
6688 or chrisbossgarlockcom
Chris Boss
Cavitation | Centrifugal Pump | Pump Packing | Sealing System
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Figure 9
Figure 10
Aside from media temperature speed and
other application variables the configurations
and operating principles of rotary-type
pumps exert different forces on the seals used
to keep them from leaking These forces can
spell the difference between acceptable seal
performance and failure
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3445
NS IDERNDUSTRIAL AUTOMATION + PROCESS CONTROL
WANT
INFORMATION
ON THE
automationindustry
SUBSCRIBE NOW at wwwiainsidercouk
Published by Spitzer and Boyes LLC Write in 15 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
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Frost says the push from developing
economies is important as the market
is technologically mature and seeing
restricted growth in developed econo-
mies This is particularly true in Europe
and North America where recent finan-
cial insta-
bility has
reduced capital expenditure across end-
user industries
Bill Moore senior vice president of
sales development and channel man-
agement for global bearings manufac-
turer SKF says ldquosmartrdquo products and
the expansion of robust reliability pro-
grams are helping to drive new invest-
ment particularly in developed coun-
tries where the cost to compete is
high Frost says the magnitude of
the existing global installed base will
strengthen the need for replacement
and upgrades adding to market de-
mand as well
Frost says despite the potential
in developing economies the focus
on price as a product differentiator
may lead to intense price pressures
among manufacturers and bring down
the value of the overall market in the
short term The growing trend among
consumers to choose low-cost Chinese
imports will complicate this challenge
As price and quality become stan-
dardized across the globe customers
will base more of their purchasing deci-
sions on value-added services accord-
ing to Frost This will push manufactur-
ers to create more maintenance-free
solutions such as lubrication-free
bearings that offer end-users savings
on service and replacement costs and
reduce downtimeldquoOffering a complete line of prod-
ucts with comprehensive services will
be another feather in the cap of ven-
dors looking to widen their consumer
baserdquo notes Frost Industrial Automa-
tion and Process Control Research
Analyst Guru Mahesh
Moore says the trend of outsourcing
manufacturing to regions where labor
and production costs are favorable is
becoming less of a factor
ldquoThe days when cheap labor made
a significant difference in where a prod-
uct is manufactured mdash particularly high
value-added products or high weight
and bulk products mdash are coming to
an end as the cost of transportation
storage and inventory balance out the
benefits of production costs where la-
bor is a smaller percentage of the cost
of manufacturingrdquo Moore says ldquoLocal
manufacturing development will indeed
come to developing countries as their
ability to create markets that generate
economies of scale that support local
production is a clear trend and one that
all manufacturers will pay attention tordquo
Moore says that development of
maintenance-free or predictive tech-
nologies and products will be a sig-
nificant advantage to everyone in the
Bearing amp Coupling Manufacturers Focus
onDEVELOPING Economies
amp EFFICIENCY InnovationBy Amy W Richardson
2 January 2015
Flow Control Magazine
|
gy
Anew study from Frost amp Sullivan (wwwfrostcom) fore-
casts steady growth for the overall bearings and couplings
market based on rapid industrial development in high-growth
regions Specifically Frost predicts development in Mexico
Indonesia Nigeria Turkey Brazil Russia India and Chinawill help boost the bearings amp couplings market from $2206
billion in 2013 to an estimated $2676 billion in 2018
The development of maintenance-freeor predictive technologies will helpboost growth in the bearings market For example SKF is developing products that will automatically notifyusers when a bearing or mechanicalrotating component is approachingthe end of its useful life Pictured hereis an SKF Microlog analyzer a por- table condition monitoring tool
COURTESY SKF
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
improved productivity through simplified solutions The powerful technology and tools ensure repeatable
reliable accurate measurements Easier access to process data allows for better troubleshooting process
optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
For daily product notes visit the lsquoFeatured Productsrsquo section flowcontrolnetworkcom
ON THE WEB
1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3845
FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
and benefits as well as grids of
instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
services provided for the
mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
Brought to you by Beamex
Your Source For Fluid Handling Videos
Go towwwflowcontrolnetworkcomfreeinfo
Select appropriate issue ofFlow Control Magazine
Select advertisements thatinterest you
Enter your email amp clickldquoSubmit Requestrdquo
1
2
3
4
PRODUCT
INFORMATION
ONLINE
Follow these 4 steps to receive freeproduct information from suppliers
FREE
FEATURED VIDEO How to Calibrate aPressure Measurement Loop
For more information about FlowTube
sponsor packs email FlowControlGrandViewMediacom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4245
THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
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One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545
![Page 17: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/17.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 174514 | January 2015 Flow Control Magazine
PPLICATIONS CORNER | Process Instrumentation
This is the final article in a series based on the troubleshoot-
ing of a mysterious unit shutdown due to flowmeter perfor-
mance problems
If yoursquove followed this column for most of 2014 you know
that what should have been a liquid ammonia stream to the
feed plant became problematic due to the occurrence of
bubbles of ammonia gas These bubbles caused an ultrasonic
flowmeter in a unit to indicate zero flow and caused the reactor
to scram (shut down) under warm operating conditions The source of the bubbles was traced back to the pres-
sure drop associated with a control valve located at the
exit of the liquid ammonia tank farm
This issue was resolved by identifying the problem
and fixing it at its source This was a pragmatic ap-
proach at the time (early 1980s) given the operation
of the cooling system in the unit and the limited selec-
tion of applicable flowmeter technologies
By the early 1990s changes were implemented that elim-
inated all process cooling requirementsmdashexcept for the small
jacketed cooler upstream of the liquid ammonia flowmeter In
other words after these changes the entire cooling system
would be operated and maintained to cool a few meters of
one small ammonia pipe Coincidently at about the same
time Coriolis mass flowmeters became more mature and
could reasonably measure the mass flow of liquid streams
with homogeneous low levels of vapor
The convergence of these two events resulted in another
approach to the problem that was not available in the early
1980smdashie install a Coriolis flowmeter that could operate in
the presence of bubbles The purchase and installation of a
Coriolis mass flowmeter was given high priority given its im-pact on unit operation economics and safety (by eliminating
the ldquomidget-makerrdquo (see March 2014 page 14))
Plant requirements and the technology that can meet
plant needs keep changing An excellent solution today can
become outdated in just a few years However there are few
substitutes for understanding fundamentals when addressing
a problem In other words there can be more than one way
to skin a cat FC
wwwspitzerandboyescom
Problem Solved AgainA Coriolis mass flowmeter provides a better solution
F o r B e t t e r P i p i ng S y s t e m P e r f o r m a nc e hellipFor Better Piping System Performancehellip
I d e a l f o r Ag g r e s s i v e C h e m i c a l s
1384 POMPTON AVENUE CEDAR GROVE NEW JERSEY 07009
973-256-3000 bull Fax 973-256-4745www p l as t om a t ic co m bull i n f o p la s t om a t ic co m
bull Rugged thermoplasticshandle corrosive andultra-pure chemicaltreatments
bull Constant pressure enhances
pump performancebull Prevents overpressure in
piping system
bull Wide range of pressuresettings
bull PTFE shaft and diaphragm designs
bull 1 4rdquo - 3rdquo sizes in PVC CPVC PVDFPolypro and PTFE
bull First State approved
thermoplastic valve for
anti-siphon applications
Write in 10 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
David W Spitzer
Ammonia Gas | Coriolis Flowmeter | David W Spitzer | Scram | Troubleshooting
FLOWSTREAM Find related content flowcontrolnetworkcom
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and Boyes
LLC offering engineering seminars strategic marketingconsulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer can be reached at 845 623-
1830 or at wwwspitzerandboyescom
The purchase and installation of a
Coriolis mass flowmeter was given
high priority given its impact on unit
operation economics and safetyldquordquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1845
Smart Valve Positioner
Beyond Control The NEW Research Controlreg SRD positioner does
everything you expect any valve positioner to do
plus more The SRDrsquos comprehensive diagnostics tool
continuously monitors for fugitive emissions delivers
real-time performance statistics and facilitates both
proactive and reactive process management Available
with integrated network communications the SRD is
compatible with Research Control valves and most other
pneumatically-actuated valves
Visit wwwbadgermetercomSmart-Valve-Positioners or
call 877-243-1010 for more information today
copy 2015 Badger Meter Inc
RESEARCH CONTROL is a registered trademark of Badger Meter Inc
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1945
Process improvements to increase yield or cut manufactur-
ing costs typically require enhanced process control but the
installed base of measurement instrumentation in a process
plant may simply be unable to facilitate improvements because
of age inadequate performance or unreliability Maintenance
cost and unscheduled process downtime for an aging process
plant can be very damaging to the balance sheet Upgrading
to new more accurate and more reliable instrumentation can
be prohibitively expensive New plant construction must alsomaintain a focus on optimizing costs for the process control
infrastructure The budget approval decision for new plant
construction must weigh such costs against projected market
conditions for the products that the plant is intended to manu-facture In todayrsquos volatile global marketplace return on invest-
ment calculations for plant upgrade or new plant construction
projects may go through several iterations before the trigger is
finally pulled or indeed not pulled
This article describes advances in two-wire instrumenta-
tion specifically in relation to flowmeters that have taken
place in the past few years and the significant cost benefits
that this new technology can realize for plant builders and op-
erators in terms of capital investment and cost of ownership
The Significance of Two-Wire Loop Power
A survey involving 204 participants in the chemical indus-try across Germany Switzerland the UK Canada and the
United States (Manfred Koenig PhD KIM Ludwigshafen
Germany 2006) revealed an 87 percent preference for two-
wire instrumentation versus four-wire in process applications
and 89 percent for utilities This overwhelming preference
may stem from the fact that older process plants were built
with two-wire twisted-pair cable networks connecting all
process units and measuring instruments together in an
overall plant control scheme
However these existing cables are relatively unsophisti-
cated and incapable of supporting anything but low-energy
instrumentation that is insensitive to interference from otherelectrical sources that might be sharing the same cable con-
duit Further the low energy levels supported by these two-
wire loops are more easily rendered safe in terms of explo-
sive risk in hazardous areas containing flammable materials
Many older process plants are also likely to have a significant
installed base of flowmeters employing pre-war (pre-1945)
technology such as positive displacement (PD) turbine vari-
able area (VA or Rotameter) and differential pressure (dP)
Market data firm Flow Research Inc (wwwflowresearch
com) indicates collectively a future compound negative annual
growth rate approaching minus 3 percent to 5 percent for PD
turbine and VA flowmeter types while dP is expected to keeppace with market growth (World Market for Flowmeters 2010)
YSTEMS DESIGN | Flow Measurement
16 | January 2015
Flow Control Magazine
The Two-Wire
ADVANTAGENew wiring options enable modern instrumentsto drive cost savings in existing plant systems
By Steve Milford
Advances in two-wire instrumentation have enabled mod- ern technology to be employed to the advantage of older
plant and process systems
Some chemical manufacturing plants are
competing for survival not only externally
against other global companies but also
internally among the global facilities of theirown company Other industry sectors face
similar challenges
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2045wwwflowcontrolnetworkcom January 2015 | 17
The Need to Replace Older TechnologiesUntil the 21st century two-wire loops were only able
to support these relatively unsophisticated instruments
which convert their measurement by various means into a
4-20mA output or pulse signal to the control system The
more advanced post-war flowmeter technologies such as
Coriolis ultrasonic or electromagnetic flowmeters have
until just eight years ago required a dedicated power sup-
ply for their function in addition to the output loop and
thus a four-wire infrastructure was required as a minimum
Therefore upgrading older two-wire meter devices to moremodern four-wire technology could require significant
expenditure in terms of the installation of separate power
cables and supply modules
There was a major breakthrough in 2006 when a true
two-wire loop-powered inline liquid ultrasonic flowmeter
was introduced (Figure 1) The nature of this breakthrough
was innovation in device power management This was the
missing piece up to that point because to be a true loop-
powered device the meter had to directly provide a full 16
mA span using less than 36 mA of remaining loop current
and less than 1 Watt of electrical energy The flowmeter
operated on a single 4-20 mA HART two-wire loop wasremotely powered by a DC supply was certified Class 1 Divi-
sion 1 and could be deployed as Intrinsically Safe through
the use of an approved safety barrier
A true two-wire loop-powered Coriolis flowmeter followed
in 2011 (Figure 2) employing a new and more advanced
common electronics platform A two-wire loop-powered inline
ultrasonic flowmeter for low-pressure gas was introduced in
2012 and a second two-wire loop-powered Coriolis meter fol-
lowed in 2013 offering improved measurement performance
and an additional high-performance meter tube material
Electromagnetic and vortex flowmeters had already been
available for some years in two-wire loop-powered form butimproved performance resulted as these designs were incor-
COURTESYENDRESS+HAUSER
Figure 1 A two-wire ultrasonic flow- meter released in 2006 operated ona single 4-20 mA two-wire loop
Write in 12 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
omegacom
reg
I I I I LL I
I I I I LL I
copy COPYRIGHT 2015 OMEGA ENGINEERING INC ALL RIGHTS RESERVED
1-888-826-6342
Prices listed are those in effect at the time of publication and are subject to change without noticePlease contact OMEGArsquos sales department for current prices
FPD3000 SeriesStarts at$630
FPD3300 SeriesStarts at
$790
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OSXL-TIM3$999
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Positive Displacement Flow Meterfor Fuels and Oils
bull Aluminum Bodybull FKM Sealsbull Temperatures up to
80ordmC (176ordmF)bull NPT or BSP Threadsbull DIN JIS or ANSI
Connection (Availableon 1 and Larger Sizes)
Positive DisplacementFlow Meter for Solvents
Thermal Imaging CameraFor Inspection andFactory Diagnosis
Note Not for ExportUSA Only
Your One-StopSource for Process
Measurement and Control
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 214518 | January 2015
Flow Control Magazine
porated into their new common electron-
ics platform in 2013 So all the ldquomodernrdquo
flow measurement technologies mdash that
is to say those introduced post-war mdash
have become available as two-wire loop-
powered devices with one exception
namely thermal mass (thermal disper-
sion) meters Unfortunately the power
requirements for this technology exceed
what is currently deemed possible withtwo-wire loop-power management
Payback forTechnology UpgradeConsider a 1rdquo process line
containing a liquid process
ingredient costing $1lb at a
mass flowrate of 150 lbmin-
ute We have $150minute
flowing in the line translating
to $9000hour and $72000
per eight-hour shift That cal-culates further to $360000
per five-day working week and
for a working year of 40 weeks for
example that is $144 million Assume
the existing device is a turbine flowmeter
Now imagine a two-wire loop-
powered Coriolis mass flowmeter is
installed in place of the existing meter
The line would need to be drained and
probably one process flange replaced
allowing the Coriolis to fit mechanically
in place of the turbine However thetwo-wire loop already used for carrying
the existing meterrsquos flow signal to the
control room can be used unaltered
for the complete electrical installation
aspects of the Coriolis flowmeter
The upside of the change is signifi-
cant and clear cut Assuming the exist-
ing meter measurement uncertainty was02 percent of reading then measure-
ment uncertainty improves through use
of Coriolis to 01 percent of reading
giving a 01100 x $14400000 im-
provement in control of the ingredient
annually or $14400 A two-wire Coriolis
mass flowmeter with 01 percent mass
flow accuracy would be paid for in ap-
proximately 6-8 months In practice the
improvement in measurement uncer-
tainty would be greater as the operator
would gain temperature and density in-formation from the Coriolis and the mea-
surement would be devoid of any fluid
property dependence Viscosity change
for example can have a major impact on
turbine meter performance Mechanical
wear and tear that turbine meters even-
tually experience which causes them to
under-register flow is precluded by mod-
ern devices like Coriolis
Furthermore if the process ingredient
was being blended with another then ad-
ditional process improvements could berealized through in-line blending control
using Coriolis technology for final density
as the control point It is possible to have
dual 4-20 mA outputs from two-wire
loop-powered meters but as the main
4-20 mA output representing the prima-
ry variable is also HART then an external
HART Loop Converter or HART IO card in
the control system can provide second-
ary tertiary and quaternary variables as
4-20 mA signals A Coriolis meter is trulya multi-variable device Certain two-wire
devices are also available with Profibus
or Foundation Fieldbus communication
Cutting Wiring CostsIn 2003 WIBEXERA (International
Instrument Usersrsquo Associations) Report
T 2732 X 03 was published and it pro- vided an average survey of prices quoted
in projects at that time for the provision
of power supplies for four-wire instru-
ments The price ranged from euro1200
to euro1800 per instrument depending
upon design and plant characteristics
for an average cost of euro1500 (about
$2000) It would be reasonable to
assume an inflationary factor of 2 per-
cent per annum giving an approximate
current-day figure of $2500
From another source within thechemical industry an estimation of
$40foot to $50foot was given for in-
stallation of four-wire cabling For a
linear 50-foot cable run with for ex-
ample a 10-foot vertical at each end
this equates to $3150 Actual costs
and budget estimates have been given
as high as $10000
The Extent of the Opportunity The modern post-war flow measure-
ment technologies have different powerrequirements and consequently they
are not all available for the
same size range in two-wire
loop-power form For example
two-wire Coriolis flowmeters
are limited to 2rdquo diameter
electromagnetic and inline
low-pressure gas ultrasonics
are limited to 8rdquo and vortex
and inline liquid ultrasonic are
limited to 12rdquo
Nevertheless for thechemical industry in particu-
lar perhaps two-thirds of the
process pipes in a plant will be no larger
than 2rdquo and even when the host process
pipe is larger a correctly sized flowmeter
can still be less than 2rdquo There is consid-
erable scope for two-wire loop-power to
deliver value for flow measurement ap-
plications with total safety
The virtues of Coriolis technology
have been covered but what about
other two-wire technologies An elec-tromagnetic flowmeter in two-wire form
YSTEMS DESIGN | Flow Measurement
In todayrsquos volatile global mar-
ketplace return on investment
calculations for plant upgrade or
new plant construction projects
may go through several itera-
tions before the trigger is finally
pulled or indeed not pulled
ldquo
rdquo
COURTESYENDRESS+HAUSER
Figure 2 Two-wire Coriolis flowme- ters became available in 2011
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2245
can be used on water wastewater or
a light water-based slurry provided the
fluid has around a 20 microSeimenscenti-
metre (microScm) electrical conductivity
A magnetic flowmeter is full bore un-
less flowrates dictate a reduced meter
size in the interests of performance and
so there are no intrusions into the flow
stream and no pressure loss An accu-
racy of 05 percent of reading is normal
from a two-wire magnetic meter and a
modest five diameters (5D) of straight in-let run is needed to avoid error from up-
stream flow disturbances When the fluid
exhibits insufficient conductivity then
the same performance and installation
requirements can be met by an inline ul-
trasonic flowmeter provided the liquid is
essentially clean and bubble-free
For gas or steam applications a vor-
tex meter is the normal choice Using a
built-in temperature sensor a two-wire
loop-powered vortex meter can calculate
mass flow of saturated steam using in-ternal steam tables An external pressure
input allows mass flow of steam to be ac-
curately calculated even when saturated
steam becomes superheated as can oc-
cur downstream of a pressure regulating
valve With mass flow known the vortex
meter can calculate energy and heat flow
A new and exciting development is
the ability of the vortex meter to indicate
wet steam and calculate dryness frac-
tion or steam quality For safety and ef-
ficiency saturated steam should be dry
and free from condensate that is to say
it should possess a high steam quality
factor However the dry or wet state of
saturated steam can sit on a knife-edge
and shift to the opposing state due to
the slightest change in process condi-
tions Rapid and reliable indication of
this change of state is now available
Perhaps the most astonishingachievement in the power management
of two-wire loop-power flowmeters is
that of the ultrasonic biogas meter It is
now possible not only to measure the
flow of wet dirty variable composition
and low-pressure anaerobic digester
gas landfill gas and coal bed methane
gas with a two-wire loop-powered ultra-
sonic flowmeter but also the same de-
vice uses an inbuilt temperature sensor
in combination with measured sound
velocity to calculate methane contentcalorific value and energy flow
Technology to Take UsForwardModern flow technologies provide instru-
ment engineers with vital self-monitoring
information The format of such infor-
mation is easier to understand and act
upon when presented in accordance
with harmonized international guidelines
for online plant asset management eg
NAMUR Standard 107
Continuous plain-text self-diagnostic
and process-related information with
suggested remedies (Figure 3) make it
possible for instrument engineers andoperators to take action at the appro-
priate time mdash immediately or during
the next scheduled shutdown mdash saving
time and money by knowing the exact
health of their measuring point and the
probable actions required to rectify any
abnormal conditions Device verifica-
tion offering third-party validated trace-
ability can be performed on demand ei-
ther locally or remotely from the control
room without the expense of a man in
the field Calibration is then avoided ordeferred without process interruption
Where a process plant has a large
installed base of older mechanical tech-
nologies the decision to embark upon a
program of replacement for plant mod-
ernization cannot of course be taken
easily There are the stocks of spare
parts to consider along with the plant
instrument technicians who are trained
on and at ease with the old devices
However a process plant that retains
the older technology going forward willbe at risk and may find it increasingly
difficult or even impossible to maintain
a cost position that competes effective-
ly in the global market FC
wwwusendresscom
wwwflowcontrolnetworkcom January 2015 | 19
Steve Milford
is a Flow Product
Business Manager
for Endress+Hauser
Inc in Greenwood
Ind He has been
involved in flow
measurement since
1983 and has been
actively involved with standards devel-
opment for flow technology within the
International Standards Organization
(ISO) and the British Standards
Institute Mr Milford can be reached
at stevemilfordusendresscom
Steve Milford
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Coriolis Flowmeter | Magnetic Flowmeter | Two-Wire | Ultrasonic Flowmeter | Vortex Flowmeter
Figure 3 A modern instrumentrsquos display module can provide continuous plain- text self-diagnostic and process-related information
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2345
The bottom line is the volume of gas under one set of
pressure and temperature conditions is not the same as it
would be for the gas under different conditions Why is thisimportant Without compensation for compressibility read-
ings taken by gas flowmeters can result in measurementsmdash
and costs to the buyermdashsignificantly lower or higher than they
should be
The flow of gas in a system can be accounted for and
reported in a number of ways such as by volume by mass
flowrate and by energy Inline turbine meters can offer both
reliability and accuracy in measuring gas flow when matched
with a monitor capable of calculating and displaying results
that have been adjusted for the nature of the gas and impor-
tantly the pressure and temperature
Measuring Flow with an Inline TurbineFlowmeter
With an inline turbine meter gas flows into the meter through
a length of piping that helps to pre-condition the flow by
reducing undesirable swirls and asymmetry Where consid-
ered necessary a flow straightener may even be installed in
line to create a uniform flow profile to the extent possible
As can be seen in Figure 1 a rotor support within the tur-
bine housing further conditions the flow and directs it through
the blades of the rotor High-precision ball bearings allow the
rotor to freely rotate on the shaft
The rotorrsquos rotational speed is directly proportional to the velocity of the fluid passing through the meter The rotor itself
incorporates magnets (or magnetic blades depending on thedesign) while the housing is non-magnetic
A proximity sensor (also known as a pickup coil) is located
in line with the rotor and detects the electrical pulses gener-
ated by the ferrous rotor spinning through the magnetic field
Each pulse represents a discrete volume of gas The out-
put frequency provides the indication of the gas flow rate and
the accumulated pulses over a specified time represent the
total volume of fluid for that measurement period
Need for Calibration The flowrate of the gas through the meter cannot be deter-
mined accurately unless the meter is calibrated The fac-tory calibration determines the meterrsquos constant known
as a K-factor which is then inputted into the gas monitor
PPLICATION NOTES | Flow Measurement
20 | January 2015
Flow Control Magazine
COMPENSATING for
Compressibility inMeasuring Gas Flow Why K-factor adjustment is essential foraccurate inline turbine flow measurement
Unlike crude oil and other liquid fossilfuels natural gas poses a challenge
in monitoring the quantity of gas flowing
through pipelines While liquids do not com-
press gases do and the mass flowrate of
gas being transmitted through gathering
lines depends on both the pressure and
temperature
By Kevin Clark
Figure 1 Internal components of a liquid turbine flowmeter
C O U R T E S Y
T U R B I N E S
I N C
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2445
Wondering Whether the
Pump Guy Seminar
Is for YouCheck out the ldquoPump Guy Insightsrdquo
video series flwctrlcompginsights
PUMP GUY INSIGHT 1NPSHa vs NPSHrmdashWhy all pumps need gauges
PUMP GUY INSIGHT 3How to Operate Your Pump at Best Efficiency
PUMP GUY INSIGHT 5Head vs Flow
PUMP GUY INSIGHT 2 Your Pumps Are Constantly Moving On Their Curves
PUMP GUY INSIGHT 4 The Role of the Pump Reliability Chain
PUMP GUY INSIGHT 6How to Read a Pump Curve
PARTNER SPONSORSFor more information and to register
for upcoming Pump Guy Seminars
visit FlowControlNetworkcomPumpGuy
7232019 Flow Control January 2015
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PPLICATION NOTES | Flow Measurement
22 | January 2015
Flow Control Magazine
Gas flowmeters measure the actual volume of gas passing
through the meter per minute irrespective of pressure and
temperature1
The volumetric flowrate of a gas is often corrected to
ldquostandardizedrdquo conditions of pressure and temperature While
ldquostandardrdquo conditions can vary depending on the definition
in the US this typically means a pressure of 1473 PSIA(pounds per square inch absolute) and a temperature of 60 F
The flowrate measurement is reported in standard cubic feet
per minute (SCFM)
Compensating for changes in pressure and temperature is
critical Consider a meter system setup for flowing conditions
of 60 PSIG (pounds per square inch gauge) and 60 F and the
line pressure decreases to 50 PSIG while the temperature
remains constant The difference in SCFM between the two
is more than 15 percent which would cost the buyer more
for the gas than it should As Table 1 demonstrates even a
small variation in pressure will result in a surprisingly high er-
ror percentage
Automation of the K-Factor The K-factor is established by an initial factory calibration In
the case of a non-compensated flow monitor any variations
in pressure and temperature will result in manual adjust-
ments needed to the K-factor In order to maintain accurate
flow measurement users must monitor pressure and temper-
ature and make corresponding adjustments to the K-factor To eliminate these manual adjustments some suppliers offer
a flow monitor that automatically adjusts for any changes in
pressure and temperature
These monitors provide accurate flow measurement regard-
less of changing environmental conditions in some cases sup-
porting applications with pressures as high as 15000 PSIG and
temperatures between -350 F to 350 F with a standard accura-
cy of +-1 percent over a flow range of 05 ACFM to 650 ACFM
Final NotesDuring the operation of a flowmeter system the ability to obtain
a readout mdash and to adjust for line pressure and temperaturechanges mdash is sometimes compromised by a lack of electric
power This issue is especially true along gas pipelines in remote
areas To overcome this limitation some manufacturers have
designed low-powered flow monitors which can operate for up
to on year on a single lithium D-cell battery
It is important for users to recognize the effects of the
compressibility of gas As such the quantity of a gas flow-
ing through a gas flowmeter depends on the pressure and
temperature In order to ensure accuracy any flowmetering
system must employ a means to correct for these effects
Otherwise the readout is certain to be in error and could be
unnecessarily costing money This is particularly crucial onwellhead production and in billing scenarios FC
wwwturbinesincorporatedcom
Notations1 The measurement factor in the US is known as the
ACFM actual cubic feet per minute (Metric units are typically
ACMH actual cubic meters per hour)
Table 1 Error induced by line pressure changes
Constant Temperature with Varying Pressure
Pressure Temperature PulsesSCF Error
50 60 2556027821 1546
51 60 2517123288 1370
52 60 2479385307 1199
53 60 2442762186 1034
54 60 240720524 873
55 60 237266858 717
56 60 2339108911 566
57 60 2306485356 418
58 60 2274759285 275
59 60 2243894166 136
60 60 2213855422 000
61 60 2184610304 132
62 60 2156127771 261
63 60 2128378378 386
64 60 210133418 508
65 60 2074968632 627
66 60 2049256506 743
67 60 2024173807 857
68 60 1999697703 967
69 60 1975806452 1075
70 60 1952479339 1181 Flow Measurement | K-Factor | Measurement
Accuracy | Turbine Flowmeter
Find related content flowcontrolnetworkcomhellipSearch on
FLOWSTREAM
Kevin Clark is senior develop-
ment engineer for Turbines Research
amp Development LLC Turbine RampD is a
subsidiary and the research and techni-
cal support arm of Turbines Inc which
serves a range of industries and applica-
tions from oil amp gas to cryogenic liquids
to custody transferKevin Clark
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2645
Pumps Bearings amp Seals TECHNOLOGY REPORT
FEATURES
SYSTEMS DESIGN
The ComplicatedCase of
Compressors
withSide-Streams
24 28 32BEST PRACTICES
How PumpingSystems
AffectSealing
Performance
TECH OUTLOOK
BearingSuppliers
Drive Gains InDeveloping
Markets
wwwflowcontrolnetworkcom January 2015 | 23
S P E C I AL S E C T I O N
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2745
The design and operation of compressors with side-
streams has always been difficult because flow entering the
compressor needs to be mixed with the core flow already
in the compressor (compressed in section-1) in a manner
that does not degrade the aerodynamic performance of sur-
rounding sections Minimizing losses and ensuring proper
mixing of the side-stream flow and core-flow are required to
ensure effective performance of a compressor of this sort
Key considerations for an application involving compres-
sors with side-stream flow include
The plant process typically dictates the side-stream
flange pressure
The impellers upstream of the side-stream should
achieve the necessary pressure for the core-flow
The side-stream flow is typically at a temperature dif-
ferent from compressor core-flow temperature
Process plants need some degree of operational flex-
ibility ie the ability to support variations in core-flow condi-
tions and side-stream conditions
Modern process plants are usually specifying more than
one operating conditions (sometimes two or more manda-
tory conditions) which can present challenges to compres-
sors with side-streams Adding to these issues modern
compressors should operate with much higher impeller tip
The COMPLICATED CASE ofCompressors with Side-StreamsConsidering key system design requirements
to ensure operational efficiency By Amin Almasi
4 January 2015
Flow Control Magazine
|
y
g
Some compressors in certain applications
have one or more incoming side-streams
(or side-loads) that introduce side-stream
flow to mix with the core flow In other words
a radial side-stream inlet is utilized in multi-
impeller centrifugal compressors to introduce
additional gas into the mid-stage of a com-
pressor This design enables optimization in
some process plants However the flow dis-
tribution after the junction of the side-stream
and the main return channel of the upstream
section can significantly affect the perfor-mance of the next section of compressor
In most cases the pressure levels at these
side-streams should be accurately predicted
to meet the theoretical performance
Compressor station at a natural gas processing plant
R U D M E R Z W E R V E R I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2845
speeds and inlet Mach numbers compared to previous
generations of compressor technology
Likewise side-streams are now com-
monly used with medium-sized and
large-sized compressors (eg 1ndash60
MW) The costs associated with cor-
rections on side-stream compres-
sor applicationsmdashany repair
inefficient operation and power
lossesmdashwould be very high Fur-
ther compressors with side-streams
are usually sensitive and difficult
machines to operate In particular
performance curves (performance
pressures efficiency etc) are sen-
sitive to suction inlet conditionsside-stream inlet conditions vol-
ume flow ratio (side-stream vol-
ume to core-flow volume) and side-stream losses
Compressors with side-stream often perform far below
expectations The main reason is that side-stream compres-
sors are different than conventional compressors (without
a side-stream) in design and operation For a compressor
with side-streams tighter tolerances in operating conditions
must be identified and applied Uncontrolled variations of
suction pressure or side-stream pressure are major prob-
lems Another major issue is the variations of the flow ratio
(side-stream flow to core-flow)
Compressor Side-Stream amp Mixing SectionIn many centrifugal compressors the portion of the side-
stream system from the flange connection to the mixing
section is similar to a compressor inlet A great challenge
is ensuring the mixing section provides circumferentially
uniform merged-flow with minimum losses This can be
achieved via effective design of the inlet configuration and
mixing section of the side-stream compressor such that
the impeller can be maintained over the whole operating
range of the compressor In many cases while there are
mixing sections provided for the machine the flows do not
completely mix before entering the impeller of the section-2
(the impeller after the mixing section) Non-uniformity at
inlet flow to the impeller is a key concern for compressor
performance
Another consideration is a compact design of the side-
stream mixing section Specifically a mixing section with
less axial length is always preferred This axial length can af-
fect the compressor rotor dynam-
ics the rotor length and over-
all compressor performance
(design cost operation and
reliability)
The side-stream exit pressure
(side-stream pressure at inlet
of the mixing section) is mainly
a function of the side-stream
flow velocity and the pres-
sure in the previous section of
the compressor Conversely the side-
stream flange pressure can depend on
side-stream flow velocity and section-1
exit conditions Therefore the side-stream
inlet flange volume flow is a function of theflange pressure compressibility (at that
pressure and temperature) and mass flow
Some engineers assume that the side-stream flange pres-
sure is equal to the inlet pressure of the first impeller of the
section-2 This is not true The mixed total pressure can be
estimated on a mass-averaged basis using side-stream total
pressure and return channel exit (section-1) total pressure
In some designs because of the lower static pressure at
the side-stream exit the total pressure at the return channel
exit is lower even though the velocity upstream is roughly
matched for both streams The pressure usually increased
at the returned channel but it can be reduced again at the
side-stream exit While simple in nature this can have an
impact on the prediction of pressure at the side-stream exit
and overall mixing section performance Based on basic flow
principles it was usually assumed that the static pressure
was equal between both flow streams at the mixing location
While this assumption might be used in rough calculations
the accurate simulations have shown this assumption is not
true In fact there are some points (for instance the shroud
wall at the exit of the return channel and the hub wall at
the exit of the side-stream) where this assumption is true
However this is not valid for all locations There are pressure
changes that occur from a side-stream flange to the inlet
of the next section (section-2) which depend on different
factors The first factor is the frictional losses due to side-
stream geometry from side-stream flange to plenum mix-
ing section etc The other factors are pressure changes due
to local curvature and geometry details of mixing section
Another consideration is the operation of a compressor
with side-stream at part-load The performance of the side-
wwwflowcontrolnetworkcom January 2015 25
Figure 1 An example of a centrifugalcompressor with side-stream
COURTESY SIEMENS
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 29456 January 2015
Flow Control Magazine
|
y
g
stream path the mixing section and
the downstream impellers when ma-
chine is operated at part-load or even
off-design operating flows will result
in additional compressor performance
problems In such a case both veloc-
ity profiles and pressure variations in
various parts (side-stream path mixing
section etc) will be different resulting
in complicated flow patterns and com-
plex aerodynamics behaviors
Side-Stream CompressorSectional Performance
Typically vendor-supplied compressor
performance curves reflect flange-to-flange performance because that is
what the plant engineers need to
evaluate the proper operation of their
system (for example from suction to
side-stream and from side-stream to
discharge) In many cases compres-
sor vendors also provide the over-
all compressor performance curves
and performance curves for section-1
(from suction to side-stream) and sec-
tion-2 (from side-stream to discharge)
Flange-to-flange data if not interpret-
ed properly can lead to false conclu-
sions about the relative performance
of individual sections of a compression
system For example if side-stream
losses from the flange to mixing sec-
tion are attributed to the downstream
section (section-2) it will cause the
downstream section (section-2) to
appear low in performance while the
upstream section (section-1) will show
high performance levels
An important behavior to con-
sider is when the actual side-stream
pressure is different than the rated
side-stream pressure When the side-
stream pressure is slightly higher than
the outlet pressure of the section-1
it (section-1) shows a relatively higher
performance compared to the real sec-
tion-1 performance In some cases
the performance of section-1 could be
considerably higher than section-2 In
other words when performance is de-
termined flange to flange the higher
flange pressure is seen as extra ldquopseu-
dordquo work done by the section (since this
is an inconsistent thermodynamic vol-
ume) resulting in a relatively high sec-
tional efficiency (section-1 shows a rel-
atively high efficiency) This is the case
for many compressors with side-stream
because the whole system is designed
(or specifically the side-stream location
is selected) in a way aimed at main-
taining the real side-stream pressure(side-stream inlet) above the section-1
outlet pressure because if the real side-
stream pressure becomes lower than
the section-1 outlet pressure the flow
may (theoretically) reverse
This is particularly important when
the side-stream mass flow is much
lower than the mass flow of core-flow
The above-mentioned reasons explain
why in many simulations calcula-
tions and performance reports related
to compressors with side-stream the
section-1 shows a relatively good ef-
ficiency and section-2 appears low in
efficiency
When the side-stream pressure is
slightly lower than the outlet pressure
of the section-1 the section-1 might
show a relatively lower performance
compared to section-2 This could oc-
cur in some recycle services where the
side-stream is actually a recycle flow
with a mass flow around two to five
times the core-flow The side-stream
(recycle) flow is returned from down-
stream of the compressor to be slightly
compressed and recycled to the down-
stream Such a recycled side-stream
compressor can present unique chal-
lenges for design and operation This
kind of machine usually needs very
special operating procedures and very
fine adjustments regarding operating
pressures and flows
Side-Stream Compressor
Performance amp Operation An important consideration is the sen-
sitivity of compressor overall perfor-
mance curve and sectional perfor-
mance curves to the flow ratio (ratio
of side-stream flow to core-flow) and
to the inlet conditions Variations in
the flow and pressure of the main
suction and side-stream inlet should
be controlled within tight tolerances
For compressors with side-stream the ASME PTC-10 code stipulates limits on
flow ratio (side-stream volume to core-
flow volume) The acceptable variation
in volume flow ratio in a compressor
with a side-stream is +-5 percent as
per ASME PTC code The requested
side-stream pressure tolerance is not
usually specified in compressor codes
but it should be around +- 2 percent
(or sometimes +- 25 percent)
Variance in flow ratio impacts the
velocity levels where the two streams
merge Significant variation in the ve-
locity profile upstream of the impeller
changes the incidence on the blade
leading edge of the following impel-
ler This change in incidence leads to a
change in sectional performance over-
all compressor performance and train
efficiency
If the flow ratio is varied between 95
percent and 105 percent (tolerances
specified in the ASME PTC-10 code)
the flange pressure changes accord-
ingly resulting in a change in the sec-
tional performance and overall perfor-
mance The sectional efficiency varies
sometimes more than +- 4 percent
This variance reduces as the flow is de-
creased toward surge However as the
flow is increased toward overload the
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3045wwwflowcontrolnetworkcom January 2015 27
variance increases up to higher values
(even in some cases three to five times
compared to variations near the surge
zone) For example in a case study
for a compressor with side-streams a
+- 5 percent variation in flow ratio and
associated changes (pressures losses
etc) the sectional efficiency reduced by
approximately 34 percent at the rated
flow at allowable operating points at
the end of curve (near the overload
ie choke) efficiency reduced by ap-
proximately 55 percent These results
show that the variation in sectional
performance and overall performance
due to flow ratio is highest at operat-ing points near the overload and low-
est at operating points near the surge
For compressors which work most of
the time at high flow (flow higher than
rated flow and discharge pressure low-
er than rated pressure) the effects of
flow ratio deviations (and subsequently
efficiency reduction) would be higher
than compressors working on the left-
hand side of curve (say with sufficient
margins near the surge)
In the compressor codes (such as
API 617) the compressor power varia-
tions should be maintained below 4
percent However in some applica-
tions clients require tighter tolerances
on the consumed power sometimes
below 2 percent (or even below 15
percent) Some studies suggest while
+- 5 percent of volume flow ratio is
suitable for performance test as per
ASME PTC-10 code some plants re-
quire tighter control on the consumed
power and compressor performance
(lower limits on the efficiency) the tol-
erances on the volume flow ratio could
be tighter than ASME PTC code In this
regard +- 4 percent tolerance can be
suggested on the volume flow ratio (ra-
tio of side-stream flow to core-flow) of
compressors with side-streams
Based on operational experiences
acceptable variations in volume flow
ratio and inlet pressures (suction inlet
and side-stream inlet) of a compressor
with side-streams are +- 4 percent
and +- 2 percent respectively
Another important consideration is
the required adjustments for the flow
ratio (side-stream flow to core-flow)
Compressors with side-stream usually
require fixed side-stream flange pres-
sures For a compressor with some variations in operation conditions (even
small changes) it is not usually pos-
sible to achieve optimum operation by
keeping the flow ratio (side-stream to
core-flow) constant The flow ratio has
to be adjusted according to the inlet
flow at which the machine is operating
in order to get the required correspond-
ing side-stream flange pressure
Thermal changes have also been
known to cause some instability in
centrifugal compressors An example is
the thermal-induced change of resid-
ual unbalance For compressors with
side-streams which feature tempera-
ture differences between core-flow and
side-stream flow the thermal behav-
ior of the compressor is usually more
complex and requires more attention
Heavy Gas ChallengeHeavy gases (such as heavy hydrocar-
bon gases eg propane propylene
MTBE (Methyl Tertiary Butyl Ether))
have very low gas sonic velocities that
produce high Mach numbers in the
aerodynamic flow paths For these
services because of high Mach num-
ber high flow coefficient stages have
very narrow flow maps characterized
by limited surge and choke margins
Compressors with side-streams in
these services present great challeng-
es This is to say the side-streams and
associated mixing further complicate
design operation and performance
prediction because the pressure tem-
perature and flow conditions at each
one of these side-streams as well
as at the exit of the machine require
stringent tolerances to optimize the
overall efficiency and performance
As such it is important to accuratelymodel design operate and moni-
tor performance characteristics of any
impellers diffusers return channels
and generally all flow-path components
in a compressor with side-stream FC
Amin Almasi
is a senior rotating
machine consultant
in Australia He is
a chartered profes- sional engineer of
Engineers Australia
(MIEAust CPEng ndash
Mechanical) and
IMechE (CEng MIMechE) holds
bachelorrsquos and masterrsquos degrees
in Mechanical Engineering and is
a registered professional engineer
in Queensland He specializes in
rotating machines including cen-
trifugal screw and reciprocating
compressors gas turbines steamturbines engines pumps subsea
offshore rotating machines LNG
units condition monitoring and reli-
ability Mr Almasi is an active mem-
ber of Engineers Australia IMechE
ASME and SPE He can be reached
at aminalmasiymailcom
Amin Almasi
Compressor | Gas Flow | Performance Curve | Side-Stream Flow
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3145
The pressure in the stuffing box
containing the packing can be estimat-
ed by the following equation
SBP = [Discharge ndash Suction] 3 + Suction
Pressure at the bottom of the stuff-
ing box will be higher than the suction
pressure but considerably lower than
the discharge pressure It should be
noted this calculation will yield a con-
servative estimate of stuffing box pres-
sure that can be further reduced by
pump design
A hole in the stuffing box serves as
a port for injecting clean fluid that cir-
culates around a lantern ring aligned
under the flush port The fluid flushes
solids back into the process to protect
the packing from abrasive wear If the
clean fluid is injected at a pressure ex-
ceeding that at the bottom of the stuff-
ing box some of it will leak back into
the process and some will leak out to
the atmosphere Recommended flush
injection pressure is 15ndash30 PSI (1ndash2
Bar) greater than the pressure at the
bottom of the stuffing box
Fluid injection is also used to lubri-
cate and cool dry-running packing that
is subject to frictional heat and to pre-
vent air from entering the pump which
reduces flow and operating efficiency
Centrifugal pumps utilize three
types of impellersmdashopen semi-open
and closed (Figures 2 3 amp 4) Open
designs prevent fluids with large solids
from clogging the impellers but at theexpense of pump efficiency Backing
plates on semi-open designs serve to
trap the fluid for more efficient opera-
tion Closed impellers are for use with
clean fluids since solids could ac-
cumulate in the eye which would re-
quire tearing down the pump to remove
them
Single-Stage CentrifugalPumpsSingle-stage centrifugal pumps typi-
cally have good bearing support of the
shaft with few run-out or ldquowhiprdquo prob-
lems However in some cases they
are subject to cavitation This occurs
in the eye of the impeller where the
fluid is under vacuum If the pressure
is low enough it will cause the material
to vaporize forming air or water vapor
bubbles As the fluid passes through
How Pumping Systems Design Affects Sealing Performance
By Chris Boss
8 January 2015
Flow Control Magazine
|
Understanding how different types of pump designs impact
sealing is critical to optimizing efficiency safety and lon-
gevity of the sealing system Used for a wide variety of media
including clear fluids solutions and slurries single-stage
centrifugal pumps are one of the most common
types (Figure 1) Fluid drawn into these pumps
enters the eye of an impeller that spins itto the outside of its container
or volute building pressure as
it moves toward discharge
Some of this fluid will work
its way behind the impeller
where it must be sealed with
compression packing or a
mechanical seal
Figure 1
Figure 2 Figure 3 Figure 4
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3245
the pump under increasing pressure
these bubbles implode sending shock
and vibration through the impeller
adversely affecting the seal This phe-
nomenon can be mitigated by running
the pump at slower speed and higher
pressure at the suction end to prevent
air from entering the fluid
Double-Ended Split-CasePumpsOperating on the same centrifugal prin-
ciple but slightly different geometry are
double-ended split-case pumps (Figure
5) Fluid enters both ends of the pump
and is directed into the eye of an impel-ler which spins it out of the volute to
discharge Packing is installed on both
the shaft and bearing ends so the stuff-
ing box is exposed only to suction pres-
sure which is usually quite low
Axial Flow Pumps Axial flow pumps operate like hydro
turbines in reverse whereby a propeller
(or axial impeller) pushes the fluid to
discharge (Figure 6)
Since the stuffing box is located
downstream of the propeller at the dis-
charge end of the pump the packing is
exposed to the full discharge pressure
Vertical PumpsVertical turbine pumps are typically
flange-mounted on a floor extending
downward into a water-filled sump
hole (Figure 7) Available as single- or
multi-stage pumps they feature an
impeller or series of impellers rotated
simultaneously by a single shaft The
impellers increase the pressure of the
upward flow subjecting the stuffing box
to full discharge pressure
Vertical pumps can be quite long so
inadequate bearing support can cause
the shaft to run out This can induce
undesirable lateral motion on the pack-
ing Worse the packing may be forced
to serve both as a bearing and a seal To
withstand these conditions the packing
should be resilient elastic and resistant
to deformation These properties rule
out packing such as graphite foil in favor
of fiber-based materials
Multi-Stage PumpsMulti-stage pumps are used for high-
pressure applications such as feeding
the boilers in steam-powered generating
plants Stuffing box pressure can vary
with pump design and number of stag-
es Designed for clean fluids and high
operating speeds these pumps typically
have high- and low-pressure ends with ahydraulic pressure equalization line run-
ning between the stuffing boxes
Like vertical pumps multi-stage
pumps feature a series of impellers to
build fluid discharge pressure In the
case of the six-stage pump pictured in
Figure 8 fluid enters at the drive end
where a stuffing box is exposed to suc-
tion pressure Channeled from one
impeller to the next through the pump
casting the fluid can reach extremely
high pressures at discharge
A second stuffing box located at the
bearing end is exposed to an intermedi-
ate pressure from the third impeller This
pressure is greater than the suction pres-
sure but much less than the discharge
pressure which can reach 2000 PSI
Fortunately the stuffing boxes in
these pumps are not exposed to dis-
charge pressures and typically see be-
low 500 PSI which is within the range
of some packing materials
wwwflowcontrolnetworkcom January 2015 29
Figure 5
Figure 6
Figure 7
Figure 8
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 33450 January 2015
Flow Control Magazine
| Gear PumpsPositive-displacement or gear pumps
operate on a different principle than
centrifugal pumps In external gear
pumps the fluid flows around the out-
side of the gears the intermeshing
of which forces it through the pump
to discharge (Figure 9) This design
makes these pumps particularly suit-
able for use with highly viscous fluids
such as resins emulsions syrups and
adhesives As such they are used for
transfer or metering applications
It should be noted gear pumps will
continue to displace fluid as long as
their shafts are turning which can pose
a problem if a clog occurs at the dis-
charge The resulting buildup of pres-
sure can blow out seals and damage
the pump Therefore most gear pumps
have pressure relief valves to divert
fluid back to the suction side for re-
circulation through the pump Internal
gear pumps operate slightly differently
but also have pressure relief valves to
prevent damage from excessive pres-
sure (Figure 10) In both external and
internal gear pumps the maximum
stuffing box pressure is determined by
these valves
Other rotating equipment includes
mixersagitators which are similar to
pumps in terms of the speeds to which
the packing is exposed There are ba-
sically three types of mixersagitators
top- bottom- and side-entry Top-entry
models are subject to the same con-
cerns about shaft run-out ldquowhiprdquo and
lateral forces on the paddles that are
encountered in some vertical pumps
Although some fluid may splash onto
the packing these mixers basically run
dry so the packing must have the abil-
ity to dissipate the resulting frictional
heat
In bottom-entry mixers the packing
is always exposed to fluid and may also
be exposed to solids requiring abra-
sion-resistance If the seal fails the en-
tire contents of the tank will eventually
drain out onto the bearings the floor
and other components under the stuff-
ing box
The packing in side-entry mixers may
be fully or intermittently exposed to flu-
id as well as side loading and vibration
Aside from media temperature
speed and other application variables
the configurations and operating prin-
ciples of rotary-type pumps exert differ-
ent forces on the seals used to keep
them from leaking These forces can
spell the difference between accept-
able seal performance and failure
Understanding these differences has
important implications that should be
taken into account to assure proper
sealing selection for long-term trou-
ble-free performance FC
wwwgarlockcom
Chris Boss is
a senior applica-
tions engineer for
Garlock Sealing
Technologies in
Palmyra NY He
has held various
positions in produc-
tion engineering
product development and applica-
tions engineering for the companyrsquos
compression packing division He
is a BSME graduate of the State
University of New York at Buffalo Mr
Boss can be reached at 800 448-
6688 or chrisbossgarlockcom
Chris Boss
Cavitation | Centrifugal Pump | Pump Packing | Sealing System
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Figure 9
Figure 10
Aside from media temperature speed and
other application variables the configurations
and operating principles of rotary-type
pumps exert different forces on the seals used
to keep them from leaking These forces can
spell the difference between acceptable seal
performance and failure
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3445
NS IDERNDUSTRIAL AUTOMATION + PROCESS CONTROL
WANT
INFORMATION
ON THE
automationindustry
SUBSCRIBE NOW at wwwiainsidercouk
Published by Spitzer and Boyes LLC Write in 15 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
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Frost says the push from developing
economies is important as the market
is technologically mature and seeing
restricted growth in developed econo-
mies This is particularly true in Europe
and North America where recent finan-
cial insta-
bility has
reduced capital expenditure across end-
user industries
Bill Moore senior vice president of
sales development and channel man-
agement for global bearings manufac-
turer SKF says ldquosmartrdquo products and
the expansion of robust reliability pro-
grams are helping to drive new invest-
ment particularly in developed coun-
tries where the cost to compete is
high Frost says the magnitude of
the existing global installed base will
strengthen the need for replacement
and upgrades adding to market de-
mand as well
Frost says despite the potential
in developing economies the focus
on price as a product differentiator
may lead to intense price pressures
among manufacturers and bring down
the value of the overall market in the
short term The growing trend among
consumers to choose low-cost Chinese
imports will complicate this challenge
As price and quality become stan-
dardized across the globe customers
will base more of their purchasing deci-
sions on value-added services accord-
ing to Frost This will push manufactur-
ers to create more maintenance-free
solutions such as lubrication-free
bearings that offer end-users savings
on service and replacement costs and
reduce downtimeldquoOffering a complete line of prod-
ucts with comprehensive services will
be another feather in the cap of ven-
dors looking to widen their consumer
baserdquo notes Frost Industrial Automa-
tion and Process Control Research
Analyst Guru Mahesh
Moore says the trend of outsourcing
manufacturing to regions where labor
and production costs are favorable is
becoming less of a factor
ldquoThe days when cheap labor made
a significant difference in where a prod-
uct is manufactured mdash particularly high
value-added products or high weight
and bulk products mdash are coming to
an end as the cost of transportation
storage and inventory balance out the
benefits of production costs where la-
bor is a smaller percentage of the cost
of manufacturingrdquo Moore says ldquoLocal
manufacturing development will indeed
come to developing countries as their
ability to create markets that generate
economies of scale that support local
production is a clear trend and one that
all manufacturers will pay attention tordquo
Moore says that development of
maintenance-free or predictive tech-
nologies and products will be a sig-
nificant advantage to everyone in the
Bearing amp Coupling Manufacturers Focus
onDEVELOPING Economies
amp EFFICIENCY InnovationBy Amy W Richardson
2 January 2015
Flow Control Magazine
|
gy
Anew study from Frost amp Sullivan (wwwfrostcom) fore-
casts steady growth for the overall bearings and couplings
market based on rapid industrial development in high-growth
regions Specifically Frost predicts development in Mexico
Indonesia Nigeria Turkey Brazil Russia India and Chinawill help boost the bearings amp couplings market from $2206
billion in 2013 to an estimated $2676 billion in 2018
The development of maintenance-freeor predictive technologies will helpboost growth in the bearings market For example SKF is developing products that will automatically notifyusers when a bearing or mechanicalrotating component is approachingthe end of its useful life Pictured hereis an SKF Microlog analyzer a por- table condition monitoring tool
COURTESY SKF
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
improved productivity through simplified solutions The powerful technology and tools ensure repeatable
reliable accurate measurements Easier access to process data allows for better troubleshooting process
optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
For daily product notes visit the lsquoFeatured Productsrsquo section flowcontrolnetworkcom
ON THE WEB
1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3845
FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
and benefits as well as grids of
instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
services provided for the
mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
Brought to you by Beamex
Your Source For Fluid Handling Videos
Go towwwflowcontrolnetworkcomfreeinfo
Select appropriate issue ofFlow Control Magazine
Select advertisements thatinterest you
Enter your email amp clickldquoSubmit Requestrdquo
1
2
3
4
PRODUCT
INFORMATION
ONLINE
Follow these 4 steps to receive freeproduct information from suppliers
FREE
FEATURED VIDEO How to Calibrate aPressure Measurement Loop
For more information about FlowTube
sponsor packs email FlowControlGrandViewMediacom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4245
THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
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Title _________________________________________________________________
Company _____________________________________________________________
AddressCityStateZip __________________________________________________
______________________________________________________________________
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One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
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7232019 Flow Control January 2015
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7232019 Flow Control January 2015
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Smart Valve Positioner
Beyond Control The NEW Research Controlreg SRD positioner does
everything you expect any valve positioner to do
plus more The SRDrsquos comprehensive diagnostics tool
continuously monitors for fugitive emissions delivers
real-time performance statistics and facilitates both
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compatible with Research Control valves and most other
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7232019 Flow Control January 2015
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Process improvements to increase yield or cut manufactur-
ing costs typically require enhanced process control but the
installed base of measurement instrumentation in a process
plant may simply be unable to facilitate improvements because
of age inadequate performance or unreliability Maintenance
cost and unscheduled process downtime for an aging process
plant can be very damaging to the balance sheet Upgrading
to new more accurate and more reliable instrumentation can
be prohibitively expensive New plant construction must alsomaintain a focus on optimizing costs for the process control
infrastructure The budget approval decision for new plant
construction must weigh such costs against projected market
conditions for the products that the plant is intended to manu-facture In todayrsquos volatile global marketplace return on invest-
ment calculations for plant upgrade or new plant construction
projects may go through several iterations before the trigger is
finally pulled or indeed not pulled
This article describes advances in two-wire instrumenta-
tion specifically in relation to flowmeters that have taken
place in the past few years and the significant cost benefits
that this new technology can realize for plant builders and op-
erators in terms of capital investment and cost of ownership
The Significance of Two-Wire Loop Power
A survey involving 204 participants in the chemical indus-try across Germany Switzerland the UK Canada and the
United States (Manfred Koenig PhD KIM Ludwigshafen
Germany 2006) revealed an 87 percent preference for two-
wire instrumentation versus four-wire in process applications
and 89 percent for utilities This overwhelming preference
may stem from the fact that older process plants were built
with two-wire twisted-pair cable networks connecting all
process units and measuring instruments together in an
overall plant control scheme
However these existing cables are relatively unsophisti-
cated and incapable of supporting anything but low-energy
instrumentation that is insensitive to interference from otherelectrical sources that might be sharing the same cable con-
duit Further the low energy levels supported by these two-
wire loops are more easily rendered safe in terms of explo-
sive risk in hazardous areas containing flammable materials
Many older process plants are also likely to have a significant
installed base of flowmeters employing pre-war (pre-1945)
technology such as positive displacement (PD) turbine vari-
able area (VA or Rotameter) and differential pressure (dP)
Market data firm Flow Research Inc (wwwflowresearch
com) indicates collectively a future compound negative annual
growth rate approaching minus 3 percent to 5 percent for PD
turbine and VA flowmeter types while dP is expected to keeppace with market growth (World Market for Flowmeters 2010)
YSTEMS DESIGN | Flow Measurement
16 | January 2015
Flow Control Magazine
The Two-Wire
ADVANTAGENew wiring options enable modern instrumentsto drive cost savings in existing plant systems
By Steve Milford
Advances in two-wire instrumentation have enabled mod- ern technology to be employed to the advantage of older
plant and process systems
Some chemical manufacturing plants are
competing for survival not only externally
against other global companies but also
internally among the global facilities of theirown company Other industry sectors face
similar challenges
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2045wwwflowcontrolnetworkcom January 2015 | 17
The Need to Replace Older TechnologiesUntil the 21st century two-wire loops were only able
to support these relatively unsophisticated instruments
which convert their measurement by various means into a
4-20mA output or pulse signal to the control system The
more advanced post-war flowmeter technologies such as
Coriolis ultrasonic or electromagnetic flowmeters have
until just eight years ago required a dedicated power sup-
ply for their function in addition to the output loop and
thus a four-wire infrastructure was required as a minimum
Therefore upgrading older two-wire meter devices to moremodern four-wire technology could require significant
expenditure in terms of the installation of separate power
cables and supply modules
There was a major breakthrough in 2006 when a true
two-wire loop-powered inline liquid ultrasonic flowmeter
was introduced (Figure 1) The nature of this breakthrough
was innovation in device power management This was the
missing piece up to that point because to be a true loop-
powered device the meter had to directly provide a full 16
mA span using less than 36 mA of remaining loop current
and less than 1 Watt of electrical energy The flowmeter
operated on a single 4-20 mA HART two-wire loop wasremotely powered by a DC supply was certified Class 1 Divi-
sion 1 and could be deployed as Intrinsically Safe through
the use of an approved safety barrier
A true two-wire loop-powered Coriolis flowmeter followed
in 2011 (Figure 2) employing a new and more advanced
common electronics platform A two-wire loop-powered inline
ultrasonic flowmeter for low-pressure gas was introduced in
2012 and a second two-wire loop-powered Coriolis meter fol-
lowed in 2013 offering improved measurement performance
and an additional high-performance meter tube material
Electromagnetic and vortex flowmeters had already been
available for some years in two-wire loop-powered form butimproved performance resulted as these designs were incor-
COURTESYENDRESS+HAUSER
Figure 1 A two-wire ultrasonic flow- meter released in 2006 operated ona single 4-20 mA two-wire loop
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I I I I LL I
I I I I LL I
copy COPYRIGHT 2015 OMEGA ENGINEERING INC ALL RIGHTS RESERVED
1-888-826-6342
Prices listed are those in effect at the time of publication and are subject to change without noticePlease contact OMEGArsquos sales department for current prices
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FPD3300 SeriesStarts at
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OSXL-TIM3$999
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Positive Displacement Flow Meterfor Fuels and Oils
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Thermal Imaging CameraFor Inspection andFactory Diagnosis
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 214518 | January 2015
Flow Control Magazine
porated into their new common electron-
ics platform in 2013 So all the ldquomodernrdquo
flow measurement technologies mdash that
is to say those introduced post-war mdash
have become available as two-wire loop-
powered devices with one exception
namely thermal mass (thermal disper-
sion) meters Unfortunately the power
requirements for this technology exceed
what is currently deemed possible withtwo-wire loop-power management
Payback forTechnology UpgradeConsider a 1rdquo process line
containing a liquid process
ingredient costing $1lb at a
mass flowrate of 150 lbmin-
ute We have $150minute
flowing in the line translating
to $9000hour and $72000
per eight-hour shift That cal-culates further to $360000
per five-day working week and
for a working year of 40 weeks for
example that is $144 million Assume
the existing device is a turbine flowmeter
Now imagine a two-wire loop-
powered Coriolis mass flowmeter is
installed in place of the existing meter
The line would need to be drained and
probably one process flange replaced
allowing the Coriolis to fit mechanically
in place of the turbine However thetwo-wire loop already used for carrying
the existing meterrsquos flow signal to the
control room can be used unaltered
for the complete electrical installation
aspects of the Coriolis flowmeter
The upside of the change is signifi-
cant and clear cut Assuming the exist-
ing meter measurement uncertainty was02 percent of reading then measure-
ment uncertainty improves through use
of Coriolis to 01 percent of reading
giving a 01100 x $14400000 im-
provement in control of the ingredient
annually or $14400 A two-wire Coriolis
mass flowmeter with 01 percent mass
flow accuracy would be paid for in ap-
proximately 6-8 months In practice the
improvement in measurement uncer-
tainty would be greater as the operator
would gain temperature and density in-formation from the Coriolis and the mea-
surement would be devoid of any fluid
property dependence Viscosity change
for example can have a major impact on
turbine meter performance Mechanical
wear and tear that turbine meters even-
tually experience which causes them to
under-register flow is precluded by mod-
ern devices like Coriolis
Furthermore if the process ingredient
was being blended with another then ad-
ditional process improvements could berealized through in-line blending control
using Coriolis technology for final density
as the control point It is possible to have
dual 4-20 mA outputs from two-wire
loop-powered meters but as the main
4-20 mA output representing the prima-
ry variable is also HART then an external
HART Loop Converter or HART IO card in
the control system can provide second-
ary tertiary and quaternary variables as
4-20 mA signals A Coriolis meter is trulya multi-variable device Certain two-wire
devices are also available with Profibus
or Foundation Fieldbus communication
Cutting Wiring CostsIn 2003 WIBEXERA (International
Instrument Usersrsquo Associations) Report
T 2732 X 03 was published and it pro- vided an average survey of prices quoted
in projects at that time for the provision
of power supplies for four-wire instru-
ments The price ranged from euro1200
to euro1800 per instrument depending
upon design and plant characteristics
for an average cost of euro1500 (about
$2000) It would be reasonable to
assume an inflationary factor of 2 per-
cent per annum giving an approximate
current-day figure of $2500
From another source within thechemical industry an estimation of
$40foot to $50foot was given for in-
stallation of four-wire cabling For a
linear 50-foot cable run with for ex-
ample a 10-foot vertical at each end
this equates to $3150 Actual costs
and budget estimates have been given
as high as $10000
The Extent of the Opportunity The modern post-war flow measure-
ment technologies have different powerrequirements and consequently they
are not all available for the
same size range in two-wire
loop-power form For example
two-wire Coriolis flowmeters
are limited to 2rdquo diameter
electromagnetic and inline
low-pressure gas ultrasonics
are limited to 8rdquo and vortex
and inline liquid ultrasonic are
limited to 12rdquo
Nevertheless for thechemical industry in particu-
lar perhaps two-thirds of the
process pipes in a plant will be no larger
than 2rdquo and even when the host process
pipe is larger a correctly sized flowmeter
can still be less than 2rdquo There is consid-
erable scope for two-wire loop-power to
deliver value for flow measurement ap-
plications with total safety
The virtues of Coriolis technology
have been covered but what about
other two-wire technologies An elec-tromagnetic flowmeter in two-wire form
YSTEMS DESIGN | Flow Measurement
In todayrsquos volatile global mar-
ketplace return on investment
calculations for plant upgrade or
new plant construction projects
may go through several itera-
tions before the trigger is finally
pulled or indeed not pulled
ldquo
rdquo
COURTESYENDRESS+HAUSER
Figure 2 Two-wire Coriolis flowme- ters became available in 2011
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2245
can be used on water wastewater or
a light water-based slurry provided the
fluid has around a 20 microSeimenscenti-
metre (microScm) electrical conductivity
A magnetic flowmeter is full bore un-
less flowrates dictate a reduced meter
size in the interests of performance and
so there are no intrusions into the flow
stream and no pressure loss An accu-
racy of 05 percent of reading is normal
from a two-wire magnetic meter and a
modest five diameters (5D) of straight in-let run is needed to avoid error from up-
stream flow disturbances When the fluid
exhibits insufficient conductivity then
the same performance and installation
requirements can be met by an inline ul-
trasonic flowmeter provided the liquid is
essentially clean and bubble-free
For gas or steam applications a vor-
tex meter is the normal choice Using a
built-in temperature sensor a two-wire
loop-powered vortex meter can calculate
mass flow of saturated steam using in-ternal steam tables An external pressure
input allows mass flow of steam to be ac-
curately calculated even when saturated
steam becomes superheated as can oc-
cur downstream of a pressure regulating
valve With mass flow known the vortex
meter can calculate energy and heat flow
A new and exciting development is
the ability of the vortex meter to indicate
wet steam and calculate dryness frac-
tion or steam quality For safety and ef-
ficiency saturated steam should be dry
and free from condensate that is to say
it should possess a high steam quality
factor However the dry or wet state of
saturated steam can sit on a knife-edge
and shift to the opposing state due to
the slightest change in process condi-
tions Rapid and reliable indication of
this change of state is now available
Perhaps the most astonishingachievement in the power management
of two-wire loop-power flowmeters is
that of the ultrasonic biogas meter It is
now possible not only to measure the
flow of wet dirty variable composition
and low-pressure anaerobic digester
gas landfill gas and coal bed methane
gas with a two-wire loop-powered ultra-
sonic flowmeter but also the same de-
vice uses an inbuilt temperature sensor
in combination with measured sound
velocity to calculate methane contentcalorific value and energy flow
Technology to Take UsForwardModern flow technologies provide instru-
ment engineers with vital self-monitoring
information The format of such infor-
mation is easier to understand and act
upon when presented in accordance
with harmonized international guidelines
for online plant asset management eg
NAMUR Standard 107
Continuous plain-text self-diagnostic
and process-related information with
suggested remedies (Figure 3) make it
possible for instrument engineers andoperators to take action at the appro-
priate time mdash immediately or during
the next scheduled shutdown mdash saving
time and money by knowing the exact
health of their measuring point and the
probable actions required to rectify any
abnormal conditions Device verifica-
tion offering third-party validated trace-
ability can be performed on demand ei-
ther locally or remotely from the control
room without the expense of a man in
the field Calibration is then avoided ordeferred without process interruption
Where a process plant has a large
installed base of older mechanical tech-
nologies the decision to embark upon a
program of replacement for plant mod-
ernization cannot of course be taken
easily There are the stocks of spare
parts to consider along with the plant
instrument technicians who are trained
on and at ease with the old devices
However a process plant that retains
the older technology going forward willbe at risk and may find it increasingly
difficult or even impossible to maintain
a cost position that competes effective-
ly in the global market FC
wwwusendresscom
wwwflowcontrolnetworkcom January 2015 | 19
Steve Milford
is a Flow Product
Business Manager
for Endress+Hauser
Inc in Greenwood
Ind He has been
involved in flow
measurement since
1983 and has been
actively involved with standards devel-
opment for flow technology within the
International Standards Organization
(ISO) and the British Standards
Institute Mr Milford can be reached
at stevemilfordusendresscom
Steve Milford
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Coriolis Flowmeter | Magnetic Flowmeter | Two-Wire | Ultrasonic Flowmeter | Vortex Flowmeter
Figure 3 A modern instrumentrsquos display module can provide continuous plain- text self-diagnostic and process-related information
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2345
The bottom line is the volume of gas under one set of
pressure and temperature conditions is not the same as it
would be for the gas under different conditions Why is thisimportant Without compensation for compressibility read-
ings taken by gas flowmeters can result in measurementsmdash
and costs to the buyermdashsignificantly lower or higher than they
should be
The flow of gas in a system can be accounted for and
reported in a number of ways such as by volume by mass
flowrate and by energy Inline turbine meters can offer both
reliability and accuracy in measuring gas flow when matched
with a monitor capable of calculating and displaying results
that have been adjusted for the nature of the gas and impor-
tantly the pressure and temperature
Measuring Flow with an Inline TurbineFlowmeter
With an inline turbine meter gas flows into the meter through
a length of piping that helps to pre-condition the flow by
reducing undesirable swirls and asymmetry Where consid-
ered necessary a flow straightener may even be installed in
line to create a uniform flow profile to the extent possible
As can be seen in Figure 1 a rotor support within the tur-
bine housing further conditions the flow and directs it through
the blades of the rotor High-precision ball bearings allow the
rotor to freely rotate on the shaft
The rotorrsquos rotational speed is directly proportional to the velocity of the fluid passing through the meter The rotor itself
incorporates magnets (or magnetic blades depending on thedesign) while the housing is non-magnetic
A proximity sensor (also known as a pickup coil) is located
in line with the rotor and detects the electrical pulses gener-
ated by the ferrous rotor spinning through the magnetic field
Each pulse represents a discrete volume of gas The out-
put frequency provides the indication of the gas flow rate and
the accumulated pulses over a specified time represent the
total volume of fluid for that measurement period
Need for Calibration The flowrate of the gas through the meter cannot be deter-
mined accurately unless the meter is calibrated The fac-tory calibration determines the meterrsquos constant known
as a K-factor which is then inputted into the gas monitor
PPLICATION NOTES | Flow Measurement
20 | January 2015
Flow Control Magazine
COMPENSATING for
Compressibility inMeasuring Gas Flow Why K-factor adjustment is essential foraccurate inline turbine flow measurement
Unlike crude oil and other liquid fossilfuels natural gas poses a challenge
in monitoring the quantity of gas flowing
through pipelines While liquids do not com-
press gases do and the mass flowrate of
gas being transmitted through gathering
lines depends on both the pressure and
temperature
By Kevin Clark
Figure 1 Internal components of a liquid turbine flowmeter
C O U R T E S Y
T U R B I N E S
I N C
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2445
Wondering Whether the
Pump Guy Seminar
Is for YouCheck out the ldquoPump Guy Insightsrdquo
video series flwctrlcompginsights
PUMP GUY INSIGHT 1NPSHa vs NPSHrmdashWhy all pumps need gauges
PUMP GUY INSIGHT 3How to Operate Your Pump at Best Efficiency
PUMP GUY INSIGHT 5Head vs Flow
PUMP GUY INSIGHT 2 Your Pumps Are Constantly Moving On Their Curves
PUMP GUY INSIGHT 4 The Role of the Pump Reliability Chain
PUMP GUY INSIGHT 6How to Read a Pump Curve
PARTNER SPONSORSFor more information and to register
for upcoming Pump Guy Seminars
visit FlowControlNetworkcomPumpGuy
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2545
PPLICATION NOTES | Flow Measurement
22 | January 2015
Flow Control Magazine
Gas flowmeters measure the actual volume of gas passing
through the meter per minute irrespective of pressure and
temperature1
The volumetric flowrate of a gas is often corrected to
ldquostandardizedrdquo conditions of pressure and temperature While
ldquostandardrdquo conditions can vary depending on the definition
in the US this typically means a pressure of 1473 PSIA(pounds per square inch absolute) and a temperature of 60 F
The flowrate measurement is reported in standard cubic feet
per minute (SCFM)
Compensating for changes in pressure and temperature is
critical Consider a meter system setup for flowing conditions
of 60 PSIG (pounds per square inch gauge) and 60 F and the
line pressure decreases to 50 PSIG while the temperature
remains constant The difference in SCFM between the two
is more than 15 percent which would cost the buyer more
for the gas than it should As Table 1 demonstrates even a
small variation in pressure will result in a surprisingly high er-
ror percentage
Automation of the K-Factor The K-factor is established by an initial factory calibration In
the case of a non-compensated flow monitor any variations
in pressure and temperature will result in manual adjust-
ments needed to the K-factor In order to maintain accurate
flow measurement users must monitor pressure and temper-
ature and make corresponding adjustments to the K-factor To eliminate these manual adjustments some suppliers offer
a flow monitor that automatically adjusts for any changes in
pressure and temperature
These monitors provide accurate flow measurement regard-
less of changing environmental conditions in some cases sup-
porting applications with pressures as high as 15000 PSIG and
temperatures between -350 F to 350 F with a standard accura-
cy of +-1 percent over a flow range of 05 ACFM to 650 ACFM
Final NotesDuring the operation of a flowmeter system the ability to obtain
a readout mdash and to adjust for line pressure and temperaturechanges mdash is sometimes compromised by a lack of electric
power This issue is especially true along gas pipelines in remote
areas To overcome this limitation some manufacturers have
designed low-powered flow monitors which can operate for up
to on year on a single lithium D-cell battery
It is important for users to recognize the effects of the
compressibility of gas As such the quantity of a gas flow-
ing through a gas flowmeter depends on the pressure and
temperature In order to ensure accuracy any flowmetering
system must employ a means to correct for these effects
Otherwise the readout is certain to be in error and could be
unnecessarily costing money This is particularly crucial onwellhead production and in billing scenarios FC
wwwturbinesincorporatedcom
Notations1 The measurement factor in the US is known as the
ACFM actual cubic feet per minute (Metric units are typically
ACMH actual cubic meters per hour)
Table 1 Error induced by line pressure changes
Constant Temperature with Varying Pressure
Pressure Temperature PulsesSCF Error
50 60 2556027821 1546
51 60 2517123288 1370
52 60 2479385307 1199
53 60 2442762186 1034
54 60 240720524 873
55 60 237266858 717
56 60 2339108911 566
57 60 2306485356 418
58 60 2274759285 275
59 60 2243894166 136
60 60 2213855422 000
61 60 2184610304 132
62 60 2156127771 261
63 60 2128378378 386
64 60 210133418 508
65 60 2074968632 627
66 60 2049256506 743
67 60 2024173807 857
68 60 1999697703 967
69 60 1975806452 1075
70 60 1952479339 1181 Flow Measurement | K-Factor | Measurement
Accuracy | Turbine Flowmeter
Find related content flowcontrolnetworkcomhellipSearch on
FLOWSTREAM
Kevin Clark is senior develop-
ment engineer for Turbines Research
amp Development LLC Turbine RampD is a
subsidiary and the research and techni-
cal support arm of Turbines Inc which
serves a range of industries and applica-
tions from oil amp gas to cryogenic liquids
to custody transferKevin Clark
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2645
Pumps Bearings amp Seals TECHNOLOGY REPORT
FEATURES
SYSTEMS DESIGN
The ComplicatedCase of
Compressors
withSide-Streams
24 28 32BEST PRACTICES
How PumpingSystems
AffectSealing
Performance
TECH OUTLOOK
BearingSuppliers
Drive Gains InDeveloping
Markets
wwwflowcontrolnetworkcom January 2015 | 23
S P E C I AL S E C T I O N
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2745
The design and operation of compressors with side-
streams has always been difficult because flow entering the
compressor needs to be mixed with the core flow already
in the compressor (compressed in section-1) in a manner
that does not degrade the aerodynamic performance of sur-
rounding sections Minimizing losses and ensuring proper
mixing of the side-stream flow and core-flow are required to
ensure effective performance of a compressor of this sort
Key considerations for an application involving compres-
sors with side-stream flow include
The plant process typically dictates the side-stream
flange pressure
The impellers upstream of the side-stream should
achieve the necessary pressure for the core-flow
The side-stream flow is typically at a temperature dif-
ferent from compressor core-flow temperature
Process plants need some degree of operational flex-
ibility ie the ability to support variations in core-flow condi-
tions and side-stream conditions
Modern process plants are usually specifying more than
one operating conditions (sometimes two or more manda-
tory conditions) which can present challenges to compres-
sors with side-streams Adding to these issues modern
compressors should operate with much higher impeller tip
The COMPLICATED CASE ofCompressors with Side-StreamsConsidering key system design requirements
to ensure operational efficiency By Amin Almasi
4 January 2015
Flow Control Magazine
|
y
g
Some compressors in certain applications
have one or more incoming side-streams
(or side-loads) that introduce side-stream
flow to mix with the core flow In other words
a radial side-stream inlet is utilized in multi-
impeller centrifugal compressors to introduce
additional gas into the mid-stage of a com-
pressor This design enables optimization in
some process plants However the flow dis-
tribution after the junction of the side-stream
and the main return channel of the upstream
section can significantly affect the perfor-mance of the next section of compressor
In most cases the pressure levels at these
side-streams should be accurately predicted
to meet the theoretical performance
Compressor station at a natural gas processing plant
R U D M E R Z W E R V E R I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2845
speeds and inlet Mach numbers compared to previous
generations of compressor technology
Likewise side-streams are now com-
monly used with medium-sized and
large-sized compressors (eg 1ndash60
MW) The costs associated with cor-
rections on side-stream compres-
sor applicationsmdashany repair
inefficient operation and power
lossesmdashwould be very high Fur-
ther compressors with side-streams
are usually sensitive and difficult
machines to operate In particular
performance curves (performance
pressures efficiency etc) are sen-
sitive to suction inlet conditionsside-stream inlet conditions vol-
ume flow ratio (side-stream vol-
ume to core-flow volume) and side-stream losses
Compressors with side-stream often perform far below
expectations The main reason is that side-stream compres-
sors are different than conventional compressors (without
a side-stream) in design and operation For a compressor
with side-streams tighter tolerances in operating conditions
must be identified and applied Uncontrolled variations of
suction pressure or side-stream pressure are major prob-
lems Another major issue is the variations of the flow ratio
(side-stream flow to core-flow)
Compressor Side-Stream amp Mixing SectionIn many centrifugal compressors the portion of the side-
stream system from the flange connection to the mixing
section is similar to a compressor inlet A great challenge
is ensuring the mixing section provides circumferentially
uniform merged-flow with minimum losses This can be
achieved via effective design of the inlet configuration and
mixing section of the side-stream compressor such that
the impeller can be maintained over the whole operating
range of the compressor In many cases while there are
mixing sections provided for the machine the flows do not
completely mix before entering the impeller of the section-2
(the impeller after the mixing section) Non-uniformity at
inlet flow to the impeller is a key concern for compressor
performance
Another consideration is a compact design of the side-
stream mixing section Specifically a mixing section with
less axial length is always preferred This axial length can af-
fect the compressor rotor dynam-
ics the rotor length and over-
all compressor performance
(design cost operation and
reliability)
The side-stream exit pressure
(side-stream pressure at inlet
of the mixing section) is mainly
a function of the side-stream
flow velocity and the pres-
sure in the previous section of
the compressor Conversely the side-
stream flange pressure can depend on
side-stream flow velocity and section-1
exit conditions Therefore the side-stream
inlet flange volume flow is a function of theflange pressure compressibility (at that
pressure and temperature) and mass flow
Some engineers assume that the side-stream flange pres-
sure is equal to the inlet pressure of the first impeller of the
section-2 This is not true The mixed total pressure can be
estimated on a mass-averaged basis using side-stream total
pressure and return channel exit (section-1) total pressure
In some designs because of the lower static pressure at
the side-stream exit the total pressure at the return channel
exit is lower even though the velocity upstream is roughly
matched for both streams The pressure usually increased
at the returned channel but it can be reduced again at the
side-stream exit While simple in nature this can have an
impact on the prediction of pressure at the side-stream exit
and overall mixing section performance Based on basic flow
principles it was usually assumed that the static pressure
was equal between both flow streams at the mixing location
While this assumption might be used in rough calculations
the accurate simulations have shown this assumption is not
true In fact there are some points (for instance the shroud
wall at the exit of the return channel and the hub wall at
the exit of the side-stream) where this assumption is true
However this is not valid for all locations There are pressure
changes that occur from a side-stream flange to the inlet
of the next section (section-2) which depend on different
factors The first factor is the frictional losses due to side-
stream geometry from side-stream flange to plenum mix-
ing section etc The other factors are pressure changes due
to local curvature and geometry details of mixing section
Another consideration is the operation of a compressor
with side-stream at part-load The performance of the side-
wwwflowcontrolnetworkcom January 2015 25
Figure 1 An example of a centrifugalcompressor with side-stream
COURTESY SIEMENS
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 29456 January 2015
Flow Control Magazine
|
y
g
stream path the mixing section and
the downstream impellers when ma-
chine is operated at part-load or even
off-design operating flows will result
in additional compressor performance
problems In such a case both veloc-
ity profiles and pressure variations in
various parts (side-stream path mixing
section etc) will be different resulting
in complicated flow patterns and com-
plex aerodynamics behaviors
Side-Stream CompressorSectional Performance
Typically vendor-supplied compressor
performance curves reflect flange-to-flange performance because that is
what the plant engineers need to
evaluate the proper operation of their
system (for example from suction to
side-stream and from side-stream to
discharge) In many cases compres-
sor vendors also provide the over-
all compressor performance curves
and performance curves for section-1
(from suction to side-stream) and sec-
tion-2 (from side-stream to discharge)
Flange-to-flange data if not interpret-
ed properly can lead to false conclu-
sions about the relative performance
of individual sections of a compression
system For example if side-stream
losses from the flange to mixing sec-
tion are attributed to the downstream
section (section-2) it will cause the
downstream section (section-2) to
appear low in performance while the
upstream section (section-1) will show
high performance levels
An important behavior to con-
sider is when the actual side-stream
pressure is different than the rated
side-stream pressure When the side-
stream pressure is slightly higher than
the outlet pressure of the section-1
it (section-1) shows a relatively higher
performance compared to the real sec-
tion-1 performance In some cases
the performance of section-1 could be
considerably higher than section-2 In
other words when performance is de-
termined flange to flange the higher
flange pressure is seen as extra ldquopseu-
dordquo work done by the section (since this
is an inconsistent thermodynamic vol-
ume) resulting in a relatively high sec-
tional efficiency (section-1 shows a rel-
atively high efficiency) This is the case
for many compressors with side-stream
because the whole system is designed
(or specifically the side-stream location
is selected) in a way aimed at main-
taining the real side-stream pressure(side-stream inlet) above the section-1
outlet pressure because if the real side-
stream pressure becomes lower than
the section-1 outlet pressure the flow
may (theoretically) reverse
This is particularly important when
the side-stream mass flow is much
lower than the mass flow of core-flow
The above-mentioned reasons explain
why in many simulations calcula-
tions and performance reports related
to compressors with side-stream the
section-1 shows a relatively good ef-
ficiency and section-2 appears low in
efficiency
When the side-stream pressure is
slightly lower than the outlet pressure
of the section-1 the section-1 might
show a relatively lower performance
compared to section-2 This could oc-
cur in some recycle services where the
side-stream is actually a recycle flow
with a mass flow around two to five
times the core-flow The side-stream
(recycle) flow is returned from down-
stream of the compressor to be slightly
compressed and recycled to the down-
stream Such a recycled side-stream
compressor can present unique chal-
lenges for design and operation This
kind of machine usually needs very
special operating procedures and very
fine adjustments regarding operating
pressures and flows
Side-Stream Compressor
Performance amp Operation An important consideration is the sen-
sitivity of compressor overall perfor-
mance curve and sectional perfor-
mance curves to the flow ratio (ratio
of side-stream flow to core-flow) and
to the inlet conditions Variations in
the flow and pressure of the main
suction and side-stream inlet should
be controlled within tight tolerances
For compressors with side-stream the ASME PTC-10 code stipulates limits on
flow ratio (side-stream volume to core-
flow volume) The acceptable variation
in volume flow ratio in a compressor
with a side-stream is +-5 percent as
per ASME PTC code The requested
side-stream pressure tolerance is not
usually specified in compressor codes
but it should be around +- 2 percent
(or sometimes +- 25 percent)
Variance in flow ratio impacts the
velocity levels where the two streams
merge Significant variation in the ve-
locity profile upstream of the impeller
changes the incidence on the blade
leading edge of the following impel-
ler This change in incidence leads to a
change in sectional performance over-
all compressor performance and train
efficiency
If the flow ratio is varied between 95
percent and 105 percent (tolerances
specified in the ASME PTC-10 code)
the flange pressure changes accord-
ingly resulting in a change in the sec-
tional performance and overall perfor-
mance The sectional efficiency varies
sometimes more than +- 4 percent
This variance reduces as the flow is de-
creased toward surge However as the
flow is increased toward overload the
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3045wwwflowcontrolnetworkcom January 2015 27
variance increases up to higher values
(even in some cases three to five times
compared to variations near the surge
zone) For example in a case study
for a compressor with side-streams a
+- 5 percent variation in flow ratio and
associated changes (pressures losses
etc) the sectional efficiency reduced by
approximately 34 percent at the rated
flow at allowable operating points at
the end of curve (near the overload
ie choke) efficiency reduced by ap-
proximately 55 percent These results
show that the variation in sectional
performance and overall performance
due to flow ratio is highest at operat-ing points near the overload and low-
est at operating points near the surge
For compressors which work most of
the time at high flow (flow higher than
rated flow and discharge pressure low-
er than rated pressure) the effects of
flow ratio deviations (and subsequently
efficiency reduction) would be higher
than compressors working on the left-
hand side of curve (say with sufficient
margins near the surge)
In the compressor codes (such as
API 617) the compressor power varia-
tions should be maintained below 4
percent However in some applica-
tions clients require tighter tolerances
on the consumed power sometimes
below 2 percent (or even below 15
percent) Some studies suggest while
+- 5 percent of volume flow ratio is
suitable for performance test as per
ASME PTC-10 code some plants re-
quire tighter control on the consumed
power and compressor performance
(lower limits on the efficiency) the tol-
erances on the volume flow ratio could
be tighter than ASME PTC code In this
regard +- 4 percent tolerance can be
suggested on the volume flow ratio (ra-
tio of side-stream flow to core-flow) of
compressors with side-streams
Based on operational experiences
acceptable variations in volume flow
ratio and inlet pressures (suction inlet
and side-stream inlet) of a compressor
with side-streams are +- 4 percent
and +- 2 percent respectively
Another important consideration is
the required adjustments for the flow
ratio (side-stream flow to core-flow)
Compressors with side-stream usually
require fixed side-stream flange pres-
sures For a compressor with some variations in operation conditions (even
small changes) it is not usually pos-
sible to achieve optimum operation by
keeping the flow ratio (side-stream to
core-flow) constant The flow ratio has
to be adjusted according to the inlet
flow at which the machine is operating
in order to get the required correspond-
ing side-stream flange pressure
Thermal changes have also been
known to cause some instability in
centrifugal compressors An example is
the thermal-induced change of resid-
ual unbalance For compressors with
side-streams which feature tempera-
ture differences between core-flow and
side-stream flow the thermal behav-
ior of the compressor is usually more
complex and requires more attention
Heavy Gas ChallengeHeavy gases (such as heavy hydrocar-
bon gases eg propane propylene
MTBE (Methyl Tertiary Butyl Ether))
have very low gas sonic velocities that
produce high Mach numbers in the
aerodynamic flow paths For these
services because of high Mach num-
ber high flow coefficient stages have
very narrow flow maps characterized
by limited surge and choke margins
Compressors with side-streams in
these services present great challeng-
es This is to say the side-streams and
associated mixing further complicate
design operation and performance
prediction because the pressure tem-
perature and flow conditions at each
one of these side-streams as well
as at the exit of the machine require
stringent tolerances to optimize the
overall efficiency and performance
As such it is important to accuratelymodel design operate and moni-
tor performance characteristics of any
impellers diffusers return channels
and generally all flow-path components
in a compressor with side-stream FC
Amin Almasi
is a senior rotating
machine consultant
in Australia He is
a chartered profes- sional engineer of
Engineers Australia
(MIEAust CPEng ndash
Mechanical) and
IMechE (CEng MIMechE) holds
bachelorrsquos and masterrsquos degrees
in Mechanical Engineering and is
a registered professional engineer
in Queensland He specializes in
rotating machines including cen-
trifugal screw and reciprocating
compressors gas turbines steamturbines engines pumps subsea
offshore rotating machines LNG
units condition monitoring and reli-
ability Mr Almasi is an active mem-
ber of Engineers Australia IMechE
ASME and SPE He can be reached
at aminalmasiymailcom
Amin Almasi
Compressor | Gas Flow | Performance Curve | Side-Stream Flow
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3145
The pressure in the stuffing box
containing the packing can be estimat-
ed by the following equation
SBP = [Discharge ndash Suction] 3 + Suction
Pressure at the bottom of the stuff-
ing box will be higher than the suction
pressure but considerably lower than
the discharge pressure It should be
noted this calculation will yield a con-
servative estimate of stuffing box pres-
sure that can be further reduced by
pump design
A hole in the stuffing box serves as
a port for injecting clean fluid that cir-
culates around a lantern ring aligned
under the flush port The fluid flushes
solids back into the process to protect
the packing from abrasive wear If the
clean fluid is injected at a pressure ex-
ceeding that at the bottom of the stuff-
ing box some of it will leak back into
the process and some will leak out to
the atmosphere Recommended flush
injection pressure is 15ndash30 PSI (1ndash2
Bar) greater than the pressure at the
bottom of the stuffing box
Fluid injection is also used to lubri-
cate and cool dry-running packing that
is subject to frictional heat and to pre-
vent air from entering the pump which
reduces flow and operating efficiency
Centrifugal pumps utilize three
types of impellersmdashopen semi-open
and closed (Figures 2 3 amp 4) Open
designs prevent fluids with large solids
from clogging the impellers but at theexpense of pump efficiency Backing
plates on semi-open designs serve to
trap the fluid for more efficient opera-
tion Closed impellers are for use with
clean fluids since solids could ac-
cumulate in the eye which would re-
quire tearing down the pump to remove
them
Single-Stage CentrifugalPumpsSingle-stage centrifugal pumps typi-
cally have good bearing support of the
shaft with few run-out or ldquowhiprdquo prob-
lems However in some cases they
are subject to cavitation This occurs
in the eye of the impeller where the
fluid is under vacuum If the pressure
is low enough it will cause the material
to vaporize forming air or water vapor
bubbles As the fluid passes through
How Pumping Systems Design Affects Sealing Performance
By Chris Boss
8 January 2015
Flow Control Magazine
|
Understanding how different types of pump designs impact
sealing is critical to optimizing efficiency safety and lon-
gevity of the sealing system Used for a wide variety of media
including clear fluids solutions and slurries single-stage
centrifugal pumps are one of the most common
types (Figure 1) Fluid drawn into these pumps
enters the eye of an impeller that spins itto the outside of its container
or volute building pressure as
it moves toward discharge
Some of this fluid will work
its way behind the impeller
where it must be sealed with
compression packing or a
mechanical seal
Figure 1
Figure 2 Figure 3 Figure 4
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3245
the pump under increasing pressure
these bubbles implode sending shock
and vibration through the impeller
adversely affecting the seal This phe-
nomenon can be mitigated by running
the pump at slower speed and higher
pressure at the suction end to prevent
air from entering the fluid
Double-Ended Split-CasePumpsOperating on the same centrifugal prin-
ciple but slightly different geometry are
double-ended split-case pumps (Figure
5) Fluid enters both ends of the pump
and is directed into the eye of an impel-ler which spins it out of the volute to
discharge Packing is installed on both
the shaft and bearing ends so the stuff-
ing box is exposed only to suction pres-
sure which is usually quite low
Axial Flow Pumps Axial flow pumps operate like hydro
turbines in reverse whereby a propeller
(or axial impeller) pushes the fluid to
discharge (Figure 6)
Since the stuffing box is located
downstream of the propeller at the dis-
charge end of the pump the packing is
exposed to the full discharge pressure
Vertical PumpsVertical turbine pumps are typically
flange-mounted on a floor extending
downward into a water-filled sump
hole (Figure 7) Available as single- or
multi-stage pumps they feature an
impeller or series of impellers rotated
simultaneously by a single shaft The
impellers increase the pressure of the
upward flow subjecting the stuffing box
to full discharge pressure
Vertical pumps can be quite long so
inadequate bearing support can cause
the shaft to run out This can induce
undesirable lateral motion on the pack-
ing Worse the packing may be forced
to serve both as a bearing and a seal To
withstand these conditions the packing
should be resilient elastic and resistant
to deformation These properties rule
out packing such as graphite foil in favor
of fiber-based materials
Multi-Stage PumpsMulti-stage pumps are used for high-
pressure applications such as feeding
the boilers in steam-powered generating
plants Stuffing box pressure can vary
with pump design and number of stag-
es Designed for clean fluids and high
operating speeds these pumps typically
have high- and low-pressure ends with ahydraulic pressure equalization line run-
ning between the stuffing boxes
Like vertical pumps multi-stage
pumps feature a series of impellers to
build fluid discharge pressure In the
case of the six-stage pump pictured in
Figure 8 fluid enters at the drive end
where a stuffing box is exposed to suc-
tion pressure Channeled from one
impeller to the next through the pump
casting the fluid can reach extremely
high pressures at discharge
A second stuffing box located at the
bearing end is exposed to an intermedi-
ate pressure from the third impeller This
pressure is greater than the suction pres-
sure but much less than the discharge
pressure which can reach 2000 PSI
Fortunately the stuffing boxes in
these pumps are not exposed to dis-
charge pressures and typically see be-
low 500 PSI which is within the range
of some packing materials
wwwflowcontrolnetworkcom January 2015 29
Figure 5
Figure 6
Figure 7
Figure 8
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 33450 January 2015
Flow Control Magazine
| Gear PumpsPositive-displacement or gear pumps
operate on a different principle than
centrifugal pumps In external gear
pumps the fluid flows around the out-
side of the gears the intermeshing
of which forces it through the pump
to discharge (Figure 9) This design
makes these pumps particularly suit-
able for use with highly viscous fluids
such as resins emulsions syrups and
adhesives As such they are used for
transfer or metering applications
It should be noted gear pumps will
continue to displace fluid as long as
their shafts are turning which can pose
a problem if a clog occurs at the dis-
charge The resulting buildup of pres-
sure can blow out seals and damage
the pump Therefore most gear pumps
have pressure relief valves to divert
fluid back to the suction side for re-
circulation through the pump Internal
gear pumps operate slightly differently
but also have pressure relief valves to
prevent damage from excessive pres-
sure (Figure 10) In both external and
internal gear pumps the maximum
stuffing box pressure is determined by
these valves
Other rotating equipment includes
mixersagitators which are similar to
pumps in terms of the speeds to which
the packing is exposed There are ba-
sically three types of mixersagitators
top- bottom- and side-entry Top-entry
models are subject to the same con-
cerns about shaft run-out ldquowhiprdquo and
lateral forces on the paddles that are
encountered in some vertical pumps
Although some fluid may splash onto
the packing these mixers basically run
dry so the packing must have the abil-
ity to dissipate the resulting frictional
heat
In bottom-entry mixers the packing
is always exposed to fluid and may also
be exposed to solids requiring abra-
sion-resistance If the seal fails the en-
tire contents of the tank will eventually
drain out onto the bearings the floor
and other components under the stuff-
ing box
The packing in side-entry mixers may
be fully or intermittently exposed to flu-
id as well as side loading and vibration
Aside from media temperature
speed and other application variables
the configurations and operating prin-
ciples of rotary-type pumps exert differ-
ent forces on the seals used to keep
them from leaking These forces can
spell the difference between accept-
able seal performance and failure
Understanding these differences has
important implications that should be
taken into account to assure proper
sealing selection for long-term trou-
ble-free performance FC
wwwgarlockcom
Chris Boss is
a senior applica-
tions engineer for
Garlock Sealing
Technologies in
Palmyra NY He
has held various
positions in produc-
tion engineering
product development and applica-
tions engineering for the companyrsquos
compression packing division He
is a BSME graduate of the State
University of New York at Buffalo Mr
Boss can be reached at 800 448-
6688 or chrisbossgarlockcom
Chris Boss
Cavitation | Centrifugal Pump | Pump Packing | Sealing System
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Figure 9
Figure 10
Aside from media temperature speed and
other application variables the configurations
and operating principles of rotary-type
pumps exert different forces on the seals used
to keep them from leaking These forces can
spell the difference between acceptable seal
performance and failure
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3445
NS IDERNDUSTRIAL AUTOMATION + PROCESS CONTROL
WANT
INFORMATION
ON THE
automationindustry
SUBSCRIBE NOW at wwwiainsidercouk
Published by Spitzer and Boyes LLC Write in 15 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3545
Frost says the push from developing
economies is important as the market
is technologically mature and seeing
restricted growth in developed econo-
mies This is particularly true in Europe
and North America where recent finan-
cial insta-
bility has
reduced capital expenditure across end-
user industries
Bill Moore senior vice president of
sales development and channel man-
agement for global bearings manufac-
turer SKF says ldquosmartrdquo products and
the expansion of robust reliability pro-
grams are helping to drive new invest-
ment particularly in developed coun-
tries where the cost to compete is
high Frost says the magnitude of
the existing global installed base will
strengthen the need for replacement
and upgrades adding to market de-
mand as well
Frost says despite the potential
in developing economies the focus
on price as a product differentiator
may lead to intense price pressures
among manufacturers and bring down
the value of the overall market in the
short term The growing trend among
consumers to choose low-cost Chinese
imports will complicate this challenge
As price and quality become stan-
dardized across the globe customers
will base more of their purchasing deci-
sions on value-added services accord-
ing to Frost This will push manufactur-
ers to create more maintenance-free
solutions such as lubrication-free
bearings that offer end-users savings
on service and replacement costs and
reduce downtimeldquoOffering a complete line of prod-
ucts with comprehensive services will
be another feather in the cap of ven-
dors looking to widen their consumer
baserdquo notes Frost Industrial Automa-
tion and Process Control Research
Analyst Guru Mahesh
Moore says the trend of outsourcing
manufacturing to regions where labor
and production costs are favorable is
becoming less of a factor
ldquoThe days when cheap labor made
a significant difference in where a prod-
uct is manufactured mdash particularly high
value-added products or high weight
and bulk products mdash are coming to
an end as the cost of transportation
storage and inventory balance out the
benefits of production costs where la-
bor is a smaller percentage of the cost
of manufacturingrdquo Moore says ldquoLocal
manufacturing development will indeed
come to developing countries as their
ability to create markets that generate
economies of scale that support local
production is a clear trend and one that
all manufacturers will pay attention tordquo
Moore says that development of
maintenance-free or predictive tech-
nologies and products will be a sig-
nificant advantage to everyone in the
Bearing amp Coupling Manufacturers Focus
onDEVELOPING Economies
amp EFFICIENCY InnovationBy Amy W Richardson
2 January 2015
Flow Control Magazine
|
gy
Anew study from Frost amp Sullivan (wwwfrostcom) fore-
casts steady growth for the overall bearings and couplings
market based on rapid industrial development in high-growth
regions Specifically Frost predicts development in Mexico
Indonesia Nigeria Turkey Brazil Russia India and Chinawill help boost the bearings amp couplings market from $2206
billion in 2013 to an estimated $2676 billion in 2018
The development of maintenance-freeor predictive technologies will helpboost growth in the bearings market For example SKF is developing products that will automatically notifyusers when a bearing or mechanicalrotating component is approachingthe end of its useful life Pictured hereis an SKF Microlog analyzer a por- table condition monitoring tool
COURTESY SKF
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
improved productivity through simplified solutions The powerful technology and tools ensure repeatable
reliable accurate measurements Easier access to process data allows for better troubleshooting process
optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
For daily product notes visit the lsquoFeatured Productsrsquo section flowcontrolnetworkcom
ON THE WEB
1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3845
FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
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detailed descriptions of features
and benefits as well as grids of
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eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
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chure details manufacturing
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ing and information about
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wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
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locating the most appropri-
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WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
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Brought to you by Beamex
Your Source For Fluid Handling Videos
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1
2
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4
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FEATURED VIDEO How to Calibrate aPressure Measurement Loop
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7232019 Flow Control January 2015
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THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
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One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545
![Page 19: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/19.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 1945
Process improvements to increase yield or cut manufactur-
ing costs typically require enhanced process control but the
installed base of measurement instrumentation in a process
plant may simply be unable to facilitate improvements because
of age inadequate performance or unreliability Maintenance
cost and unscheduled process downtime for an aging process
plant can be very damaging to the balance sheet Upgrading
to new more accurate and more reliable instrumentation can
be prohibitively expensive New plant construction must alsomaintain a focus on optimizing costs for the process control
infrastructure The budget approval decision for new plant
construction must weigh such costs against projected market
conditions for the products that the plant is intended to manu-facture In todayrsquos volatile global marketplace return on invest-
ment calculations for plant upgrade or new plant construction
projects may go through several iterations before the trigger is
finally pulled or indeed not pulled
This article describes advances in two-wire instrumenta-
tion specifically in relation to flowmeters that have taken
place in the past few years and the significant cost benefits
that this new technology can realize for plant builders and op-
erators in terms of capital investment and cost of ownership
The Significance of Two-Wire Loop Power
A survey involving 204 participants in the chemical indus-try across Germany Switzerland the UK Canada and the
United States (Manfred Koenig PhD KIM Ludwigshafen
Germany 2006) revealed an 87 percent preference for two-
wire instrumentation versus four-wire in process applications
and 89 percent for utilities This overwhelming preference
may stem from the fact that older process plants were built
with two-wire twisted-pair cable networks connecting all
process units and measuring instruments together in an
overall plant control scheme
However these existing cables are relatively unsophisti-
cated and incapable of supporting anything but low-energy
instrumentation that is insensitive to interference from otherelectrical sources that might be sharing the same cable con-
duit Further the low energy levels supported by these two-
wire loops are more easily rendered safe in terms of explo-
sive risk in hazardous areas containing flammable materials
Many older process plants are also likely to have a significant
installed base of flowmeters employing pre-war (pre-1945)
technology such as positive displacement (PD) turbine vari-
able area (VA or Rotameter) and differential pressure (dP)
Market data firm Flow Research Inc (wwwflowresearch
com) indicates collectively a future compound negative annual
growth rate approaching minus 3 percent to 5 percent for PD
turbine and VA flowmeter types while dP is expected to keeppace with market growth (World Market for Flowmeters 2010)
YSTEMS DESIGN | Flow Measurement
16 | January 2015
Flow Control Magazine
The Two-Wire
ADVANTAGENew wiring options enable modern instrumentsto drive cost savings in existing plant systems
By Steve Milford
Advances in two-wire instrumentation have enabled mod- ern technology to be employed to the advantage of older
plant and process systems
Some chemical manufacturing plants are
competing for survival not only externally
against other global companies but also
internally among the global facilities of theirown company Other industry sectors face
similar challenges
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2045wwwflowcontrolnetworkcom January 2015 | 17
The Need to Replace Older TechnologiesUntil the 21st century two-wire loops were only able
to support these relatively unsophisticated instruments
which convert their measurement by various means into a
4-20mA output or pulse signal to the control system The
more advanced post-war flowmeter technologies such as
Coriolis ultrasonic or electromagnetic flowmeters have
until just eight years ago required a dedicated power sup-
ply for their function in addition to the output loop and
thus a four-wire infrastructure was required as a minimum
Therefore upgrading older two-wire meter devices to moremodern four-wire technology could require significant
expenditure in terms of the installation of separate power
cables and supply modules
There was a major breakthrough in 2006 when a true
two-wire loop-powered inline liquid ultrasonic flowmeter
was introduced (Figure 1) The nature of this breakthrough
was innovation in device power management This was the
missing piece up to that point because to be a true loop-
powered device the meter had to directly provide a full 16
mA span using less than 36 mA of remaining loop current
and less than 1 Watt of electrical energy The flowmeter
operated on a single 4-20 mA HART two-wire loop wasremotely powered by a DC supply was certified Class 1 Divi-
sion 1 and could be deployed as Intrinsically Safe through
the use of an approved safety barrier
A true two-wire loop-powered Coriolis flowmeter followed
in 2011 (Figure 2) employing a new and more advanced
common electronics platform A two-wire loop-powered inline
ultrasonic flowmeter for low-pressure gas was introduced in
2012 and a second two-wire loop-powered Coriolis meter fol-
lowed in 2013 offering improved measurement performance
and an additional high-performance meter tube material
Electromagnetic and vortex flowmeters had already been
available for some years in two-wire loop-powered form butimproved performance resulted as these designs were incor-
COURTESYENDRESS+HAUSER
Figure 1 A two-wire ultrasonic flow- meter released in 2006 operated ona single 4-20 mA two-wire loop
Write in 12 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
omegacom
reg
I I I I LL I
I I I I LL I
copy COPYRIGHT 2015 OMEGA ENGINEERING INC ALL RIGHTS RESERVED
1-888-826-6342
Prices listed are those in effect at the time of publication and are subject to change without noticePlease contact OMEGArsquos sales department for current prices
FPD3000 SeriesStarts at$630
FPD3300 SeriesStarts at
$790
Visit omegacomfpd3000
Visit omegacomfpd3300
OSXL-TIM3$999
Visitomegacomosxl-tim3
Positive Displacement Flow Meterfor Fuels and Oils
bull Aluminum Bodybull FKM Sealsbull Temperatures up to
80ordmC (176ordmF)bull NPT or BSP Threadsbull DIN JIS or ANSI
Connection (Availableon 1 and Larger Sizes)
Positive DisplacementFlow Meter for Solvents
Thermal Imaging CameraFor Inspection andFactory Diagnosis
Note Not for ExportUSA Only
Your One-StopSource for Process
Measurement and Control
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 214518 | January 2015
Flow Control Magazine
porated into their new common electron-
ics platform in 2013 So all the ldquomodernrdquo
flow measurement technologies mdash that
is to say those introduced post-war mdash
have become available as two-wire loop-
powered devices with one exception
namely thermal mass (thermal disper-
sion) meters Unfortunately the power
requirements for this technology exceed
what is currently deemed possible withtwo-wire loop-power management
Payback forTechnology UpgradeConsider a 1rdquo process line
containing a liquid process
ingredient costing $1lb at a
mass flowrate of 150 lbmin-
ute We have $150minute
flowing in the line translating
to $9000hour and $72000
per eight-hour shift That cal-culates further to $360000
per five-day working week and
for a working year of 40 weeks for
example that is $144 million Assume
the existing device is a turbine flowmeter
Now imagine a two-wire loop-
powered Coriolis mass flowmeter is
installed in place of the existing meter
The line would need to be drained and
probably one process flange replaced
allowing the Coriolis to fit mechanically
in place of the turbine However thetwo-wire loop already used for carrying
the existing meterrsquos flow signal to the
control room can be used unaltered
for the complete electrical installation
aspects of the Coriolis flowmeter
The upside of the change is signifi-
cant and clear cut Assuming the exist-
ing meter measurement uncertainty was02 percent of reading then measure-
ment uncertainty improves through use
of Coriolis to 01 percent of reading
giving a 01100 x $14400000 im-
provement in control of the ingredient
annually or $14400 A two-wire Coriolis
mass flowmeter with 01 percent mass
flow accuracy would be paid for in ap-
proximately 6-8 months In practice the
improvement in measurement uncer-
tainty would be greater as the operator
would gain temperature and density in-formation from the Coriolis and the mea-
surement would be devoid of any fluid
property dependence Viscosity change
for example can have a major impact on
turbine meter performance Mechanical
wear and tear that turbine meters even-
tually experience which causes them to
under-register flow is precluded by mod-
ern devices like Coriolis
Furthermore if the process ingredient
was being blended with another then ad-
ditional process improvements could berealized through in-line blending control
using Coriolis technology for final density
as the control point It is possible to have
dual 4-20 mA outputs from two-wire
loop-powered meters but as the main
4-20 mA output representing the prima-
ry variable is also HART then an external
HART Loop Converter or HART IO card in
the control system can provide second-
ary tertiary and quaternary variables as
4-20 mA signals A Coriolis meter is trulya multi-variable device Certain two-wire
devices are also available with Profibus
or Foundation Fieldbus communication
Cutting Wiring CostsIn 2003 WIBEXERA (International
Instrument Usersrsquo Associations) Report
T 2732 X 03 was published and it pro- vided an average survey of prices quoted
in projects at that time for the provision
of power supplies for four-wire instru-
ments The price ranged from euro1200
to euro1800 per instrument depending
upon design and plant characteristics
for an average cost of euro1500 (about
$2000) It would be reasonable to
assume an inflationary factor of 2 per-
cent per annum giving an approximate
current-day figure of $2500
From another source within thechemical industry an estimation of
$40foot to $50foot was given for in-
stallation of four-wire cabling For a
linear 50-foot cable run with for ex-
ample a 10-foot vertical at each end
this equates to $3150 Actual costs
and budget estimates have been given
as high as $10000
The Extent of the Opportunity The modern post-war flow measure-
ment technologies have different powerrequirements and consequently they
are not all available for the
same size range in two-wire
loop-power form For example
two-wire Coriolis flowmeters
are limited to 2rdquo diameter
electromagnetic and inline
low-pressure gas ultrasonics
are limited to 8rdquo and vortex
and inline liquid ultrasonic are
limited to 12rdquo
Nevertheless for thechemical industry in particu-
lar perhaps two-thirds of the
process pipes in a plant will be no larger
than 2rdquo and even when the host process
pipe is larger a correctly sized flowmeter
can still be less than 2rdquo There is consid-
erable scope for two-wire loop-power to
deliver value for flow measurement ap-
plications with total safety
The virtues of Coriolis technology
have been covered but what about
other two-wire technologies An elec-tromagnetic flowmeter in two-wire form
YSTEMS DESIGN | Flow Measurement
In todayrsquos volatile global mar-
ketplace return on investment
calculations for plant upgrade or
new plant construction projects
may go through several itera-
tions before the trigger is finally
pulled or indeed not pulled
ldquo
rdquo
COURTESYENDRESS+HAUSER
Figure 2 Two-wire Coriolis flowme- ters became available in 2011
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2245
can be used on water wastewater or
a light water-based slurry provided the
fluid has around a 20 microSeimenscenti-
metre (microScm) electrical conductivity
A magnetic flowmeter is full bore un-
less flowrates dictate a reduced meter
size in the interests of performance and
so there are no intrusions into the flow
stream and no pressure loss An accu-
racy of 05 percent of reading is normal
from a two-wire magnetic meter and a
modest five diameters (5D) of straight in-let run is needed to avoid error from up-
stream flow disturbances When the fluid
exhibits insufficient conductivity then
the same performance and installation
requirements can be met by an inline ul-
trasonic flowmeter provided the liquid is
essentially clean and bubble-free
For gas or steam applications a vor-
tex meter is the normal choice Using a
built-in temperature sensor a two-wire
loop-powered vortex meter can calculate
mass flow of saturated steam using in-ternal steam tables An external pressure
input allows mass flow of steam to be ac-
curately calculated even when saturated
steam becomes superheated as can oc-
cur downstream of a pressure regulating
valve With mass flow known the vortex
meter can calculate energy and heat flow
A new and exciting development is
the ability of the vortex meter to indicate
wet steam and calculate dryness frac-
tion or steam quality For safety and ef-
ficiency saturated steam should be dry
and free from condensate that is to say
it should possess a high steam quality
factor However the dry or wet state of
saturated steam can sit on a knife-edge
and shift to the opposing state due to
the slightest change in process condi-
tions Rapid and reliable indication of
this change of state is now available
Perhaps the most astonishingachievement in the power management
of two-wire loop-power flowmeters is
that of the ultrasonic biogas meter It is
now possible not only to measure the
flow of wet dirty variable composition
and low-pressure anaerobic digester
gas landfill gas and coal bed methane
gas with a two-wire loop-powered ultra-
sonic flowmeter but also the same de-
vice uses an inbuilt temperature sensor
in combination with measured sound
velocity to calculate methane contentcalorific value and energy flow
Technology to Take UsForwardModern flow technologies provide instru-
ment engineers with vital self-monitoring
information The format of such infor-
mation is easier to understand and act
upon when presented in accordance
with harmonized international guidelines
for online plant asset management eg
NAMUR Standard 107
Continuous plain-text self-diagnostic
and process-related information with
suggested remedies (Figure 3) make it
possible for instrument engineers andoperators to take action at the appro-
priate time mdash immediately or during
the next scheduled shutdown mdash saving
time and money by knowing the exact
health of their measuring point and the
probable actions required to rectify any
abnormal conditions Device verifica-
tion offering third-party validated trace-
ability can be performed on demand ei-
ther locally or remotely from the control
room without the expense of a man in
the field Calibration is then avoided ordeferred without process interruption
Where a process plant has a large
installed base of older mechanical tech-
nologies the decision to embark upon a
program of replacement for plant mod-
ernization cannot of course be taken
easily There are the stocks of spare
parts to consider along with the plant
instrument technicians who are trained
on and at ease with the old devices
However a process plant that retains
the older technology going forward willbe at risk and may find it increasingly
difficult or even impossible to maintain
a cost position that competes effective-
ly in the global market FC
wwwusendresscom
wwwflowcontrolnetworkcom January 2015 | 19
Steve Milford
is a Flow Product
Business Manager
for Endress+Hauser
Inc in Greenwood
Ind He has been
involved in flow
measurement since
1983 and has been
actively involved with standards devel-
opment for flow technology within the
International Standards Organization
(ISO) and the British Standards
Institute Mr Milford can be reached
at stevemilfordusendresscom
Steve Milford
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Coriolis Flowmeter | Magnetic Flowmeter | Two-Wire | Ultrasonic Flowmeter | Vortex Flowmeter
Figure 3 A modern instrumentrsquos display module can provide continuous plain- text self-diagnostic and process-related information
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2345
The bottom line is the volume of gas under one set of
pressure and temperature conditions is not the same as it
would be for the gas under different conditions Why is thisimportant Without compensation for compressibility read-
ings taken by gas flowmeters can result in measurementsmdash
and costs to the buyermdashsignificantly lower or higher than they
should be
The flow of gas in a system can be accounted for and
reported in a number of ways such as by volume by mass
flowrate and by energy Inline turbine meters can offer both
reliability and accuracy in measuring gas flow when matched
with a monitor capable of calculating and displaying results
that have been adjusted for the nature of the gas and impor-
tantly the pressure and temperature
Measuring Flow with an Inline TurbineFlowmeter
With an inline turbine meter gas flows into the meter through
a length of piping that helps to pre-condition the flow by
reducing undesirable swirls and asymmetry Where consid-
ered necessary a flow straightener may even be installed in
line to create a uniform flow profile to the extent possible
As can be seen in Figure 1 a rotor support within the tur-
bine housing further conditions the flow and directs it through
the blades of the rotor High-precision ball bearings allow the
rotor to freely rotate on the shaft
The rotorrsquos rotational speed is directly proportional to the velocity of the fluid passing through the meter The rotor itself
incorporates magnets (or magnetic blades depending on thedesign) while the housing is non-magnetic
A proximity sensor (also known as a pickup coil) is located
in line with the rotor and detects the electrical pulses gener-
ated by the ferrous rotor spinning through the magnetic field
Each pulse represents a discrete volume of gas The out-
put frequency provides the indication of the gas flow rate and
the accumulated pulses over a specified time represent the
total volume of fluid for that measurement period
Need for Calibration The flowrate of the gas through the meter cannot be deter-
mined accurately unless the meter is calibrated The fac-tory calibration determines the meterrsquos constant known
as a K-factor which is then inputted into the gas monitor
PPLICATION NOTES | Flow Measurement
20 | January 2015
Flow Control Magazine
COMPENSATING for
Compressibility inMeasuring Gas Flow Why K-factor adjustment is essential foraccurate inline turbine flow measurement
Unlike crude oil and other liquid fossilfuels natural gas poses a challenge
in monitoring the quantity of gas flowing
through pipelines While liquids do not com-
press gases do and the mass flowrate of
gas being transmitted through gathering
lines depends on both the pressure and
temperature
By Kevin Clark
Figure 1 Internal components of a liquid turbine flowmeter
C O U R T E S Y
T U R B I N E S
I N C
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2445
Wondering Whether the
Pump Guy Seminar
Is for YouCheck out the ldquoPump Guy Insightsrdquo
video series flwctrlcompginsights
PUMP GUY INSIGHT 1NPSHa vs NPSHrmdashWhy all pumps need gauges
PUMP GUY INSIGHT 3How to Operate Your Pump at Best Efficiency
PUMP GUY INSIGHT 5Head vs Flow
PUMP GUY INSIGHT 2 Your Pumps Are Constantly Moving On Their Curves
PUMP GUY INSIGHT 4 The Role of the Pump Reliability Chain
PUMP GUY INSIGHT 6How to Read a Pump Curve
PARTNER SPONSORSFor more information and to register
for upcoming Pump Guy Seminars
visit FlowControlNetworkcomPumpGuy
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2545
PPLICATION NOTES | Flow Measurement
22 | January 2015
Flow Control Magazine
Gas flowmeters measure the actual volume of gas passing
through the meter per minute irrespective of pressure and
temperature1
The volumetric flowrate of a gas is often corrected to
ldquostandardizedrdquo conditions of pressure and temperature While
ldquostandardrdquo conditions can vary depending on the definition
in the US this typically means a pressure of 1473 PSIA(pounds per square inch absolute) and a temperature of 60 F
The flowrate measurement is reported in standard cubic feet
per minute (SCFM)
Compensating for changes in pressure and temperature is
critical Consider a meter system setup for flowing conditions
of 60 PSIG (pounds per square inch gauge) and 60 F and the
line pressure decreases to 50 PSIG while the temperature
remains constant The difference in SCFM between the two
is more than 15 percent which would cost the buyer more
for the gas than it should As Table 1 demonstrates even a
small variation in pressure will result in a surprisingly high er-
ror percentage
Automation of the K-Factor The K-factor is established by an initial factory calibration In
the case of a non-compensated flow monitor any variations
in pressure and temperature will result in manual adjust-
ments needed to the K-factor In order to maintain accurate
flow measurement users must monitor pressure and temper-
ature and make corresponding adjustments to the K-factor To eliminate these manual adjustments some suppliers offer
a flow monitor that automatically adjusts for any changes in
pressure and temperature
These monitors provide accurate flow measurement regard-
less of changing environmental conditions in some cases sup-
porting applications with pressures as high as 15000 PSIG and
temperatures between -350 F to 350 F with a standard accura-
cy of +-1 percent over a flow range of 05 ACFM to 650 ACFM
Final NotesDuring the operation of a flowmeter system the ability to obtain
a readout mdash and to adjust for line pressure and temperaturechanges mdash is sometimes compromised by a lack of electric
power This issue is especially true along gas pipelines in remote
areas To overcome this limitation some manufacturers have
designed low-powered flow monitors which can operate for up
to on year on a single lithium D-cell battery
It is important for users to recognize the effects of the
compressibility of gas As such the quantity of a gas flow-
ing through a gas flowmeter depends on the pressure and
temperature In order to ensure accuracy any flowmetering
system must employ a means to correct for these effects
Otherwise the readout is certain to be in error and could be
unnecessarily costing money This is particularly crucial onwellhead production and in billing scenarios FC
wwwturbinesincorporatedcom
Notations1 The measurement factor in the US is known as the
ACFM actual cubic feet per minute (Metric units are typically
ACMH actual cubic meters per hour)
Table 1 Error induced by line pressure changes
Constant Temperature with Varying Pressure
Pressure Temperature PulsesSCF Error
50 60 2556027821 1546
51 60 2517123288 1370
52 60 2479385307 1199
53 60 2442762186 1034
54 60 240720524 873
55 60 237266858 717
56 60 2339108911 566
57 60 2306485356 418
58 60 2274759285 275
59 60 2243894166 136
60 60 2213855422 000
61 60 2184610304 132
62 60 2156127771 261
63 60 2128378378 386
64 60 210133418 508
65 60 2074968632 627
66 60 2049256506 743
67 60 2024173807 857
68 60 1999697703 967
69 60 1975806452 1075
70 60 1952479339 1181 Flow Measurement | K-Factor | Measurement
Accuracy | Turbine Flowmeter
Find related content flowcontrolnetworkcomhellipSearch on
FLOWSTREAM
Kevin Clark is senior develop-
ment engineer for Turbines Research
amp Development LLC Turbine RampD is a
subsidiary and the research and techni-
cal support arm of Turbines Inc which
serves a range of industries and applica-
tions from oil amp gas to cryogenic liquids
to custody transferKevin Clark
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2645
Pumps Bearings amp Seals TECHNOLOGY REPORT
FEATURES
SYSTEMS DESIGN
The ComplicatedCase of
Compressors
withSide-Streams
24 28 32BEST PRACTICES
How PumpingSystems
AffectSealing
Performance
TECH OUTLOOK
BearingSuppliers
Drive Gains InDeveloping
Markets
wwwflowcontrolnetworkcom January 2015 | 23
S P E C I AL S E C T I O N
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2745
The design and operation of compressors with side-
streams has always been difficult because flow entering the
compressor needs to be mixed with the core flow already
in the compressor (compressed in section-1) in a manner
that does not degrade the aerodynamic performance of sur-
rounding sections Minimizing losses and ensuring proper
mixing of the side-stream flow and core-flow are required to
ensure effective performance of a compressor of this sort
Key considerations for an application involving compres-
sors with side-stream flow include
The plant process typically dictates the side-stream
flange pressure
The impellers upstream of the side-stream should
achieve the necessary pressure for the core-flow
The side-stream flow is typically at a temperature dif-
ferent from compressor core-flow temperature
Process plants need some degree of operational flex-
ibility ie the ability to support variations in core-flow condi-
tions and side-stream conditions
Modern process plants are usually specifying more than
one operating conditions (sometimes two or more manda-
tory conditions) which can present challenges to compres-
sors with side-streams Adding to these issues modern
compressors should operate with much higher impeller tip
The COMPLICATED CASE ofCompressors with Side-StreamsConsidering key system design requirements
to ensure operational efficiency By Amin Almasi
4 January 2015
Flow Control Magazine
|
y
g
Some compressors in certain applications
have one or more incoming side-streams
(or side-loads) that introduce side-stream
flow to mix with the core flow In other words
a radial side-stream inlet is utilized in multi-
impeller centrifugal compressors to introduce
additional gas into the mid-stage of a com-
pressor This design enables optimization in
some process plants However the flow dis-
tribution after the junction of the side-stream
and the main return channel of the upstream
section can significantly affect the perfor-mance of the next section of compressor
In most cases the pressure levels at these
side-streams should be accurately predicted
to meet the theoretical performance
Compressor station at a natural gas processing plant
R U D M E R Z W E R V E R I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2845
speeds and inlet Mach numbers compared to previous
generations of compressor technology
Likewise side-streams are now com-
monly used with medium-sized and
large-sized compressors (eg 1ndash60
MW) The costs associated with cor-
rections on side-stream compres-
sor applicationsmdashany repair
inefficient operation and power
lossesmdashwould be very high Fur-
ther compressors with side-streams
are usually sensitive and difficult
machines to operate In particular
performance curves (performance
pressures efficiency etc) are sen-
sitive to suction inlet conditionsside-stream inlet conditions vol-
ume flow ratio (side-stream vol-
ume to core-flow volume) and side-stream losses
Compressors with side-stream often perform far below
expectations The main reason is that side-stream compres-
sors are different than conventional compressors (without
a side-stream) in design and operation For a compressor
with side-streams tighter tolerances in operating conditions
must be identified and applied Uncontrolled variations of
suction pressure or side-stream pressure are major prob-
lems Another major issue is the variations of the flow ratio
(side-stream flow to core-flow)
Compressor Side-Stream amp Mixing SectionIn many centrifugal compressors the portion of the side-
stream system from the flange connection to the mixing
section is similar to a compressor inlet A great challenge
is ensuring the mixing section provides circumferentially
uniform merged-flow with minimum losses This can be
achieved via effective design of the inlet configuration and
mixing section of the side-stream compressor such that
the impeller can be maintained over the whole operating
range of the compressor In many cases while there are
mixing sections provided for the machine the flows do not
completely mix before entering the impeller of the section-2
(the impeller after the mixing section) Non-uniformity at
inlet flow to the impeller is a key concern for compressor
performance
Another consideration is a compact design of the side-
stream mixing section Specifically a mixing section with
less axial length is always preferred This axial length can af-
fect the compressor rotor dynam-
ics the rotor length and over-
all compressor performance
(design cost operation and
reliability)
The side-stream exit pressure
(side-stream pressure at inlet
of the mixing section) is mainly
a function of the side-stream
flow velocity and the pres-
sure in the previous section of
the compressor Conversely the side-
stream flange pressure can depend on
side-stream flow velocity and section-1
exit conditions Therefore the side-stream
inlet flange volume flow is a function of theflange pressure compressibility (at that
pressure and temperature) and mass flow
Some engineers assume that the side-stream flange pres-
sure is equal to the inlet pressure of the first impeller of the
section-2 This is not true The mixed total pressure can be
estimated on a mass-averaged basis using side-stream total
pressure and return channel exit (section-1) total pressure
In some designs because of the lower static pressure at
the side-stream exit the total pressure at the return channel
exit is lower even though the velocity upstream is roughly
matched for both streams The pressure usually increased
at the returned channel but it can be reduced again at the
side-stream exit While simple in nature this can have an
impact on the prediction of pressure at the side-stream exit
and overall mixing section performance Based on basic flow
principles it was usually assumed that the static pressure
was equal between both flow streams at the mixing location
While this assumption might be used in rough calculations
the accurate simulations have shown this assumption is not
true In fact there are some points (for instance the shroud
wall at the exit of the return channel and the hub wall at
the exit of the side-stream) where this assumption is true
However this is not valid for all locations There are pressure
changes that occur from a side-stream flange to the inlet
of the next section (section-2) which depend on different
factors The first factor is the frictional losses due to side-
stream geometry from side-stream flange to plenum mix-
ing section etc The other factors are pressure changes due
to local curvature and geometry details of mixing section
Another consideration is the operation of a compressor
with side-stream at part-load The performance of the side-
wwwflowcontrolnetworkcom January 2015 25
Figure 1 An example of a centrifugalcompressor with side-stream
COURTESY SIEMENS
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 29456 January 2015
Flow Control Magazine
|
y
g
stream path the mixing section and
the downstream impellers when ma-
chine is operated at part-load or even
off-design operating flows will result
in additional compressor performance
problems In such a case both veloc-
ity profiles and pressure variations in
various parts (side-stream path mixing
section etc) will be different resulting
in complicated flow patterns and com-
plex aerodynamics behaviors
Side-Stream CompressorSectional Performance
Typically vendor-supplied compressor
performance curves reflect flange-to-flange performance because that is
what the plant engineers need to
evaluate the proper operation of their
system (for example from suction to
side-stream and from side-stream to
discharge) In many cases compres-
sor vendors also provide the over-
all compressor performance curves
and performance curves for section-1
(from suction to side-stream) and sec-
tion-2 (from side-stream to discharge)
Flange-to-flange data if not interpret-
ed properly can lead to false conclu-
sions about the relative performance
of individual sections of a compression
system For example if side-stream
losses from the flange to mixing sec-
tion are attributed to the downstream
section (section-2) it will cause the
downstream section (section-2) to
appear low in performance while the
upstream section (section-1) will show
high performance levels
An important behavior to con-
sider is when the actual side-stream
pressure is different than the rated
side-stream pressure When the side-
stream pressure is slightly higher than
the outlet pressure of the section-1
it (section-1) shows a relatively higher
performance compared to the real sec-
tion-1 performance In some cases
the performance of section-1 could be
considerably higher than section-2 In
other words when performance is de-
termined flange to flange the higher
flange pressure is seen as extra ldquopseu-
dordquo work done by the section (since this
is an inconsistent thermodynamic vol-
ume) resulting in a relatively high sec-
tional efficiency (section-1 shows a rel-
atively high efficiency) This is the case
for many compressors with side-stream
because the whole system is designed
(or specifically the side-stream location
is selected) in a way aimed at main-
taining the real side-stream pressure(side-stream inlet) above the section-1
outlet pressure because if the real side-
stream pressure becomes lower than
the section-1 outlet pressure the flow
may (theoretically) reverse
This is particularly important when
the side-stream mass flow is much
lower than the mass flow of core-flow
The above-mentioned reasons explain
why in many simulations calcula-
tions and performance reports related
to compressors with side-stream the
section-1 shows a relatively good ef-
ficiency and section-2 appears low in
efficiency
When the side-stream pressure is
slightly lower than the outlet pressure
of the section-1 the section-1 might
show a relatively lower performance
compared to section-2 This could oc-
cur in some recycle services where the
side-stream is actually a recycle flow
with a mass flow around two to five
times the core-flow The side-stream
(recycle) flow is returned from down-
stream of the compressor to be slightly
compressed and recycled to the down-
stream Such a recycled side-stream
compressor can present unique chal-
lenges for design and operation This
kind of machine usually needs very
special operating procedures and very
fine adjustments regarding operating
pressures and flows
Side-Stream Compressor
Performance amp Operation An important consideration is the sen-
sitivity of compressor overall perfor-
mance curve and sectional perfor-
mance curves to the flow ratio (ratio
of side-stream flow to core-flow) and
to the inlet conditions Variations in
the flow and pressure of the main
suction and side-stream inlet should
be controlled within tight tolerances
For compressors with side-stream the ASME PTC-10 code stipulates limits on
flow ratio (side-stream volume to core-
flow volume) The acceptable variation
in volume flow ratio in a compressor
with a side-stream is +-5 percent as
per ASME PTC code The requested
side-stream pressure tolerance is not
usually specified in compressor codes
but it should be around +- 2 percent
(or sometimes +- 25 percent)
Variance in flow ratio impacts the
velocity levels where the two streams
merge Significant variation in the ve-
locity profile upstream of the impeller
changes the incidence on the blade
leading edge of the following impel-
ler This change in incidence leads to a
change in sectional performance over-
all compressor performance and train
efficiency
If the flow ratio is varied between 95
percent and 105 percent (tolerances
specified in the ASME PTC-10 code)
the flange pressure changes accord-
ingly resulting in a change in the sec-
tional performance and overall perfor-
mance The sectional efficiency varies
sometimes more than +- 4 percent
This variance reduces as the flow is de-
creased toward surge However as the
flow is increased toward overload the
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3045wwwflowcontrolnetworkcom January 2015 27
variance increases up to higher values
(even in some cases three to five times
compared to variations near the surge
zone) For example in a case study
for a compressor with side-streams a
+- 5 percent variation in flow ratio and
associated changes (pressures losses
etc) the sectional efficiency reduced by
approximately 34 percent at the rated
flow at allowable operating points at
the end of curve (near the overload
ie choke) efficiency reduced by ap-
proximately 55 percent These results
show that the variation in sectional
performance and overall performance
due to flow ratio is highest at operat-ing points near the overload and low-
est at operating points near the surge
For compressors which work most of
the time at high flow (flow higher than
rated flow and discharge pressure low-
er than rated pressure) the effects of
flow ratio deviations (and subsequently
efficiency reduction) would be higher
than compressors working on the left-
hand side of curve (say with sufficient
margins near the surge)
In the compressor codes (such as
API 617) the compressor power varia-
tions should be maintained below 4
percent However in some applica-
tions clients require tighter tolerances
on the consumed power sometimes
below 2 percent (or even below 15
percent) Some studies suggest while
+- 5 percent of volume flow ratio is
suitable for performance test as per
ASME PTC-10 code some plants re-
quire tighter control on the consumed
power and compressor performance
(lower limits on the efficiency) the tol-
erances on the volume flow ratio could
be tighter than ASME PTC code In this
regard +- 4 percent tolerance can be
suggested on the volume flow ratio (ra-
tio of side-stream flow to core-flow) of
compressors with side-streams
Based on operational experiences
acceptable variations in volume flow
ratio and inlet pressures (suction inlet
and side-stream inlet) of a compressor
with side-streams are +- 4 percent
and +- 2 percent respectively
Another important consideration is
the required adjustments for the flow
ratio (side-stream flow to core-flow)
Compressors with side-stream usually
require fixed side-stream flange pres-
sures For a compressor with some variations in operation conditions (even
small changes) it is not usually pos-
sible to achieve optimum operation by
keeping the flow ratio (side-stream to
core-flow) constant The flow ratio has
to be adjusted according to the inlet
flow at which the machine is operating
in order to get the required correspond-
ing side-stream flange pressure
Thermal changes have also been
known to cause some instability in
centrifugal compressors An example is
the thermal-induced change of resid-
ual unbalance For compressors with
side-streams which feature tempera-
ture differences between core-flow and
side-stream flow the thermal behav-
ior of the compressor is usually more
complex and requires more attention
Heavy Gas ChallengeHeavy gases (such as heavy hydrocar-
bon gases eg propane propylene
MTBE (Methyl Tertiary Butyl Ether))
have very low gas sonic velocities that
produce high Mach numbers in the
aerodynamic flow paths For these
services because of high Mach num-
ber high flow coefficient stages have
very narrow flow maps characterized
by limited surge and choke margins
Compressors with side-streams in
these services present great challeng-
es This is to say the side-streams and
associated mixing further complicate
design operation and performance
prediction because the pressure tem-
perature and flow conditions at each
one of these side-streams as well
as at the exit of the machine require
stringent tolerances to optimize the
overall efficiency and performance
As such it is important to accuratelymodel design operate and moni-
tor performance characteristics of any
impellers diffusers return channels
and generally all flow-path components
in a compressor with side-stream FC
Amin Almasi
is a senior rotating
machine consultant
in Australia He is
a chartered profes- sional engineer of
Engineers Australia
(MIEAust CPEng ndash
Mechanical) and
IMechE (CEng MIMechE) holds
bachelorrsquos and masterrsquos degrees
in Mechanical Engineering and is
a registered professional engineer
in Queensland He specializes in
rotating machines including cen-
trifugal screw and reciprocating
compressors gas turbines steamturbines engines pumps subsea
offshore rotating machines LNG
units condition monitoring and reli-
ability Mr Almasi is an active mem-
ber of Engineers Australia IMechE
ASME and SPE He can be reached
at aminalmasiymailcom
Amin Almasi
Compressor | Gas Flow | Performance Curve | Side-Stream Flow
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3145
The pressure in the stuffing box
containing the packing can be estimat-
ed by the following equation
SBP = [Discharge ndash Suction] 3 + Suction
Pressure at the bottom of the stuff-
ing box will be higher than the suction
pressure but considerably lower than
the discharge pressure It should be
noted this calculation will yield a con-
servative estimate of stuffing box pres-
sure that can be further reduced by
pump design
A hole in the stuffing box serves as
a port for injecting clean fluid that cir-
culates around a lantern ring aligned
under the flush port The fluid flushes
solids back into the process to protect
the packing from abrasive wear If the
clean fluid is injected at a pressure ex-
ceeding that at the bottom of the stuff-
ing box some of it will leak back into
the process and some will leak out to
the atmosphere Recommended flush
injection pressure is 15ndash30 PSI (1ndash2
Bar) greater than the pressure at the
bottom of the stuffing box
Fluid injection is also used to lubri-
cate and cool dry-running packing that
is subject to frictional heat and to pre-
vent air from entering the pump which
reduces flow and operating efficiency
Centrifugal pumps utilize three
types of impellersmdashopen semi-open
and closed (Figures 2 3 amp 4) Open
designs prevent fluids with large solids
from clogging the impellers but at theexpense of pump efficiency Backing
plates on semi-open designs serve to
trap the fluid for more efficient opera-
tion Closed impellers are for use with
clean fluids since solids could ac-
cumulate in the eye which would re-
quire tearing down the pump to remove
them
Single-Stage CentrifugalPumpsSingle-stage centrifugal pumps typi-
cally have good bearing support of the
shaft with few run-out or ldquowhiprdquo prob-
lems However in some cases they
are subject to cavitation This occurs
in the eye of the impeller where the
fluid is under vacuum If the pressure
is low enough it will cause the material
to vaporize forming air or water vapor
bubbles As the fluid passes through
How Pumping Systems Design Affects Sealing Performance
By Chris Boss
8 January 2015
Flow Control Magazine
|
Understanding how different types of pump designs impact
sealing is critical to optimizing efficiency safety and lon-
gevity of the sealing system Used for a wide variety of media
including clear fluids solutions and slurries single-stage
centrifugal pumps are one of the most common
types (Figure 1) Fluid drawn into these pumps
enters the eye of an impeller that spins itto the outside of its container
or volute building pressure as
it moves toward discharge
Some of this fluid will work
its way behind the impeller
where it must be sealed with
compression packing or a
mechanical seal
Figure 1
Figure 2 Figure 3 Figure 4
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3245
the pump under increasing pressure
these bubbles implode sending shock
and vibration through the impeller
adversely affecting the seal This phe-
nomenon can be mitigated by running
the pump at slower speed and higher
pressure at the suction end to prevent
air from entering the fluid
Double-Ended Split-CasePumpsOperating on the same centrifugal prin-
ciple but slightly different geometry are
double-ended split-case pumps (Figure
5) Fluid enters both ends of the pump
and is directed into the eye of an impel-ler which spins it out of the volute to
discharge Packing is installed on both
the shaft and bearing ends so the stuff-
ing box is exposed only to suction pres-
sure which is usually quite low
Axial Flow Pumps Axial flow pumps operate like hydro
turbines in reverse whereby a propeller
(or axial impeller) pushes the fluid to
discharge (Figure 6)
Since the stuffing box is located
downstream of the propeller at the dis-
charge end of the pump the packing is
exposed to the full discharge pressure
Vertical PumpsVertical turbine pumps are typically
flange-mounted on a floor extending
downward into a water-filled sump
hole (Figure 7) Available as single- or
multi-stage pumps they feature an
impeller or series of impellers rotated
simultaneously by a single shaft The
impellers increase the pressure of the
upward flow subjecting the stuffing box
to full discharge pressure
Vertical pumps can be quite long so
inadequate bearing support can cause
the shaft to run out This can induce
undesirable lateral motion on the pack-
ing Worse the packing may be forced
to serve both as a bearing and a seal To
withstand these conditions the packing
should be resilient elastic and resistant
to deformation These properties rule
out packing such as graphite foil in favor
of fiber-based materials
Multi-Stage PumpsMulti-stage pumps are used for high-
pressure applications such as feeding
the boilers in steam-powered generating
plants Stuffing box pressure can vary
with pump design and number of stag-
es Designed for clean fluids and high
operating speeds these pumps typically
have high- and low-pressure ends with ahydraulic pressure equalization line run-
ning between the stuffing boxes
Like vertical pumps multi-stage
pumps feature a series of impellers to
build fluid discharge pressure In the
case of the six-stage pump pictured in
Figure 8 fluid enters at the drive end
where a stuffing box is exposed to suc-
tion pressure Channeled from one
impeller to the next through the pump
casting the fluid can reach extremely
high pressures at discharge
A second stuffing box located at the
bearing end is exposed to an intermedi-
ate pressure from the third impeller This
pressure is greater than the suction pres-
sure but much less than the discharge
pressure which can reach 2000 PSI
Fortunately the stuffing boxes in
these pumps are not exposed to dis-
charge pressures and typically see be-
low 500 PSI which is within the range
of some packing materials
wwwflowcontrolnetworkcom January 2015 29
Figure 5
Figure 6
Figure 7
Figure 8
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 33450 January 2015
Flow Control Magazine
| Gear PumpsPositive-displacement or gear pumps
operate on a different principle than
centrifugal pumps In external gear
pumps the fluid flows around the out-
side of the gears the intermeshing
of which forces it through the pump
to discharge (Figure 9) This design
makes these pumps particularly suit-
able for use with highly viscous fluids
such as resins emulsions syrups and
adhesives As such they are used for
transfer or metering applications
It should be noted gear pumps will
continue to displace fluid as long as
their shafts are turning which can pose
a problem if a clog occurs at the dis-
charge The resulting buildup of pres-
sure can blow out seals and damage
the pump Therefore most gear pumps
have pressure relief valves to divert
fluid back to the suction side for re-
circulation through the pump Internal
gear pumps operate slightly differently
but also have pressure relief valves to
prevent damage from excessive pres-
sure (Figure 10) In both external and
internal gear pumps the maximum
stuffing box pressure is determined by
these valves
Other rotating equipment includes
mixersagitators which are similar to
pumps in terms of the speeds to which
the packing is exposed There are ba-
sically three types of mixersagitators
top- bottom- and side-entry Top-entry
models are subject to the same con-
cerns about shaft run-out ldquowhiprdquo and
lateral forces on the paddles that are
encountered in some vertical pumps
Although some fluid may splash onto
the packing these mixers basically run
dry so the packing must have the abil-
ity to dissipate the resulting frictional
heat
In bottom-entry mixers the packing
is always exposed to fluid and may also
be exposed to solids requiring abra-
sion-resistance If the seal fails the en-
tire contents of the tank will eventually
drain out onto the bearings the floor
and other components under the stuff-
ing box
The packing in side-entry mixers may
be fully or intermittently exposed to flu-
id as well as side loading and vibration
Aside from media temperature
speed and other application variables
the configurations and operating prin-
ciples of rotary-type pumps exert differ-
ent forces on the seals used to keep
them from leaking These forces can
spell the difference between accept-
able seal performance and failure
Understanding these differences has
important implications that should be
taken into account to assure proper
sealing selection for long-term trou-
ble-free performance FC
wwwgarlockcom
Chris Boss is
a senior applica-
tions engineer for
Garlock Sealing
Technologies in
Palmyra NY He
has held various
positions in produc-
tion engineering
product development and applica-
tions engineering for the companyrsquos
compression packing division He
is a BSME graduate of the State
University of New York at Buffalo Mr
Boss can be reached at 800 448-
6688 or chrisbossgarlockcom
Chris Boss
Cavitation | Centrifugal Pump | Pump Packing | Sealing System
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Figure 9
Figure 10
Aside from media temperature speed and
other application variables the configurations
and operating principles of rotary-type
pumps exert different forces on the seals used
to keep them from leaking These forces can
spell the difference between acceptable seal
performance and failure
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3445
NS IDERNDUSTRIAL AUTOMATION + PROCESS CONTROL
WANT
INFORMATION
ON THE
automationindustry
SUBSCRIBE NOW at wwwiainsidercouk
Published by Spitzer and Boyes LLC Write in 15 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
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Frost says the push from developing
economies is important as the market
is technologically mature and seeing
restricted growth in developed econo-
mies This is particularly true in Europe
and North America where recent finan-
cial insta-
bility has
reduced capital expenditure across end-
user industries
Bill Moore senior vice president of
sales development and channel man-
agement for global bearings manufac-
turer SKF says ldquosmartrdquo products and
the expansion of robust reliability pro-
grams are helping to drive new invest-
ment particularly in developed coun-
tries where the cost to compete is
high Frost says the magnitude of
the existing global installed base will
strengthen the need for replacement
and upgrades adding to market de-
mand as well
Frost says despite the potential
in developing economies the focus
on price as a product differentiator
may lead to intense price pressures
among manufacturers and bring down
the value of the overall market in the
short term The growing trend among
consumers to choose low-cost Chinese
imports will complicate this challenge
As price and quality become stan-
dardized across the globe customers
will base more of their purchasing deci-
sions on value-added services accord-
ing to Frost This will push manufactur-
ers to create more maintenance-free
solutions such as lubrication-free
bearings that offer end-users savings
on service and replacement costs and
reduce downtimeldquoOffering a complete line of prod-
ucts with comprehensive services will
be another feather in the cap of ven-
dors looking to widen their consumer
baserdquo notes Frost Industrial Automa-
tion and Process Control Research
Analyst Guru Mahesh
Moore says the trend of outsourcing
manufacturing to regions where labor
and production costs are favorable is
becoming less of a factor
ldquoThe days when cheap labor made
a significant difference in where a prod-
uct is manufactured mdash particularly high
value-added products or high weight
and bulk products mdash are coming to
an end as the cost of transportation
storage and inventory balance out the
benefits of production costs where la-
bor is a smaller percentage of the cost
of manufacturingrdquo Moore says ldquoLocal
manufacturing development will indeed
come to developing countries as their
ability to create markets that generate
economies of scale that support local
production is a clear trend and one that
all manufacturers will pay attention tordquo
Moore says that development of
maintenance-free or predictive tech-
nologies and products will be a sig-
nificant advantage to everyone in the
Bearing amp Coupling Manufacturers Focus
onDEVELOPING Economies
amp EFFICIENCY InnovationBy Amy W Richardson
2 January 2015
Flow Control Magazine
|
gy
Anew study from Frost amp Sullivan (wwwfrostcom) fore-
casts steady growth for the overall bearings and couplings
market based on rapid industrial development in high-growth
regions Specifically Frost predicts development in Mexico
Indonesia Nigeria Turkey Brazil Russia India and Chinawill help boost the bearings amp couplings market from $2206
billion in 2013 to an estimated $2676 billion in 2018
The development of maintenance-freeor predictive technologies will helpboost growth in the bearings market For example SKF is developing products that will automatically notifyusers when a bearing or mechanicalrotating component is approachingthe end of its useful life Pictured hereis an SKF Microlog analyzer a por- table condition monitoring tool
COURTESY SKF
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
improved productivity through simplified solutions The powerful technology and tools ensure repeatable
reliable accurate measurements Easier access to process data allows for better troubleshooting process
optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
For daily product notes visit the lsquoFeatured Productsrsquo section flowcontrolnetworkcom
ON THE WEB
1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3845
FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
and benefits as well as grids of
instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
services provided for the
mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
Brought to you by Beamex
Your Source For Fluid Handling Videos
Go towwwflowcontrolnetworkcomfreeinfo
Select appropriate issue ofFlow Control Magazine
Select advertisements thatinterest you
Enter your email amp clickldquoSubmit Requestrdquo
1
2
3
4
PRODUCT
INFORMATION
ONLINE
Follow these 4 steps to receive freeproduct information from suppliers
FREE
FEATURED VIDEO How to Calibrate aPressure Measurement Loop
For more information about FlowTube
sponsor packs email FlowControlGrandViewMediacom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4245
THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
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Title _________________________________________________________________
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______________________________________________________________________
Phone ________________________________________________________________
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One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
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7232019 Flow Control January 2015
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![Page 20: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/20.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2045wwwflowcontrolnetworkcom January 2015 | 17
The Need to Replace Older TechnologiesUntil the 21st century two-wire loops were only able
to support these relatively unsophisticated instruments
which convert their measurement by various means into a
4-20mA output or pulse signal to the control system The
more advanced post-war flowmeter technologies such as
Coriolis ultrasonic or electromagnetic flowmeters have
until just eight years ago required a dedicated power sup-
ply for their function in addition to the output loop and
thus a four-wire infrastructure was required as a minimum
Therefore upgrading older two-wire meter devices to moremodern four-wire technology could require significant
expenditure in terms of the installation of separate power
cables and supply modules
There was a major breakthrough in 2006 when a true
two-wire loop-powered inline liquid ultrasonic flowmeter
was introduced (Figure 1) The nature of this breakthrough
was innovation in device power management This was the
missing piece up to that point because to be a true loop-
powered device the meter had to directly provide a full 16
mA span using less than 36 mA of remaining loop current
and less than 1 Watt of electrical energy The flowmeter
operated on a single 4-20 mA HART two-wire loop wasremotely powered by a DC supply was certified Class 1 Divi-
sion 1 and could be deployed as Intrinsically Safe through
the use of an approved safety barrier
A true two-wire loop-powered Coriolis flowmeter followed
in 2011 (Figure 2) employing a new and more advanced
common electronics platform A two-wire loop-powered inline
ultrasonic flowmeter for low-pressure gas was introduced in
2012 and a second two-wire loop-powered Coriolis meter fol-
lowed in 2013 offering improved measurement performance
and an additional high-performance meter tube material
Electromagnetic and vortex flowmeters had already been
available for some years in two-wire loop-powered form butimproved performance resulted as these designs were incor-
COURTESYENDRESS+HAUSER
Figure 1 A two-wire ultrasonic flow- meter released in 2006 operated ona single 4-20 mA two-wire loop
Write in 12 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
omegacom
reg
I I I I LL I
I I I I LL I
copy COPYRIGHT 2015 OMEGA ENGINEERING INC ALL RIGHTS RESERVED
1-888-826-6342
Prices listed are those in effect at the time of publication and are subject to change without noticePlease contact OMEGArsquos sales department for current prices
FPD3000 SeriesStarts at$630
FPD3300 SeriesStarts at
$790
Visit omegacomfpd3000
Visit omegacomfpd3300
OSXL-TIM3$999
Visitomegacomosxl-tim3
Positive Displacement Flow Meterfor Fuels and Oils
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Connection (Availableon 1 and Larger Sizes)
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Thermal Imaging CameraFor Inspection andFactory Diagnosis
Note Not for ExportUSA Only
Your One-StopSource for Process
Measurement and Control
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 214518 | January 2015
Flow Control Magazine
porated into their new common electron-
ics platform in 2013 So all the ldquomodernrdquo
flow measurement technologies mdash that
is to say those introduced post-war mdash
have become available as two-wire loop-
powered devices with one exception
namely thermal mass (thermal disper-
sion) meters Unfortunately the power
requirements for this technology exceed
what is currently deemed possible withtwo-wire loop-power management
Payback forTechnology UpgradeConsider a 1rdquo process line
containing a liquid process
ingredient costing $1lb at a
mass flowrate of 150 lbmin-
ute We have $150minute
flowing in the line translating
to $9000hour and $72000
per eight-hour shift That cal-culates further to $360000
per five-day working week and
for a working year of 40 weeks for
example that is $144 million Assume
the existing device is a turbine flowmeter
Now imagine a two-wire loop-
powered Coriolis mass flowmeter is
installed in place of the existing meter
The line would need to be drained and
probably one process flange replaced
allowing the Coriolis to fit mechanically
in place of the turbine However thetwo-wire loop already used for carrying
the existing meterrsquos flow signal to the
control room can be used unaltered
for the complete electrical installation
aspects of the Coriolis flowmeter
The upside of the change is signifi-
cant and clear cut Assuming the exist-
ing meter measurement uncertainty was02 percent of reading then measure-
ment uncertainty improves through use
of Coriolis to 01 percent of reading
giving a 01100 x $14400000 im-
provement in control of the ingredient
annually or $14400 A two-wire Coriolis
mass flowmeter with 01 percent mass
flow accuracy would be paid for in ap-
proximately 6-8 months In practice the
improvement in measurement uncer-
tainty would be greater as the operator
would gain temperature and density in-formation from the Coriolis and the mea-
surement would be devoid of any fluid
property dependence Viscosity change
for example can have a major impact on
turbine meter performance Mechanical
wear and tear that turbine meters even-
tually experience which causes them to
under-register flow is precluded by mod-
ern devices like Coriolis
Furthermore if the process ingredient
was being blended with another then ad-
ditional process improvements could berealized through in-line blending control
using Coriolis technology for final density
as the control point It is possible to have
dual 4-20 mA outputs from two-wire
loop-powered meters but as the main
4-20 mA output representing the prima-
ry variable is also HART then an external
HART Loop Converter or HART IO card in
the control system can provide second-
ary tertiary and quaternary variables as
4-20 mA signals A Coriolis meter is trulya multi-variable device Certain two-wire
devices are also available with Profibus
or Foundation Fieldbus communication
Cutting Wiring CostsIn 2003 WIBEXERA (International
Instrument Usersrsquo Associations) Report
T 2732 X 03 was published and it pro- vided an average survey of prices quoted
in projects at that time for the provision
of power supplies for four-wire instru-
ments The price ranged from euro1200
to euro1800 per instrument depending
upon design and plant characteristics
for an average cost of euro1500 (about
$2000) It would be reasonable to
assume an inflationary factor of 2 per-
cent per annum giving an approximate
current-day figure of $2500
From another source within thechemical industry an estimation of
$40foot to $50foot was given for in-
stallation of four-wire cabling For a
linear 50-foot cable run with for ex-
ample a 10-foot vertical at each end
this equates to $3150 Actual costs
and budget estimates have been given
as high as $10000
The Extent of the Opportunity The modern post-war flow measure-
ment technologies have different powerrequirements and consequently they
are not all available for the
same size range in two-wire
loop-power form For example
two-wire Coriolis flowmeters
are limited to 2rdquo diameter
electromagnetic and inline
low-pressure gas ultrasonics
are limited to 8rdquo and vortex
and inline liquid ultrasonic are
limited to 12rdquo
Nevertheless for thechemical industry in particu-
lar perhaps two-thirds of the
process pipes in a plant will be no larger
than 2rdquo and even when the host process
pipe is larger a correctly sized flowmeter
can still be less than 2rdquo There is consid-
erable scope for two-wire loop-power to
deliver value for flow measurement ap-
plications with total safety
The virtues of Coriolis technology
have been covered but what about
other two-wire technologies An elec-tromagnetic flowmeter in two-wire form
YSTEMS DESIGN | Flow Measurement
In todayrsquos volatile global mar-
ketplace return on investment
calculations for plant upgrade or
new plant construction projects
may go through several itera-
tions before the trigger is finally
pulled or indeed not pulled
ldquo
rdquo
COURTESYENDRESS+HAUSER
Figure 2 Two-wire Coriolis flowme- ters became available in 2011
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2245
can be used on water wastewater or
a light water-based slurry provided the
fluid has around a 20 microSeimenscenti-
metre (microScm) electrical conductivity
A magnetic flowmeter is full bore un-
less flowrates dictate a reduced meter
size in the interests of performance and
so there are no intrusions into the flow
stream and no pressure loss An accu-
racy of 05 percent of reading is normal
from a two-wire magnetic meter and a
modest five diameters (5D) of straight in-let run is needed to avoid error from up-
stream flow disturbances When the fluid
exhibits insufficient conductivity then
the same performance and installation
requirements can be met by an inline ul-
trasonic flowmeter provided the liquid is
essentially clean and bubble-free
For gas or steam applications a vor-
tex meter is the normal choice Using a
built-in temperature sensor a two-wire
loop-powered vortex meter can calculate
mass flow of saturated steam using in-ternal steam tables An external pressure
input allows mass flow of steam to be ac-
curately calculated even when saturated
steam becomes superheated as can oc-
cur downstream of a pressure regulating
valve With mass flow known the vortex
meter can calculate energy and heat flow
A new and exciting development is
the ability of the vortex meter to indicate
wet steam and calculate dryness frac-
tion or steam quality For safety and ef-
ficiency saturated steam should be dry
and free from condensate that is to say
it should possess a high steam quality
factor However the dry or wet state of
saturated steam can sit on a knife-edge
and shift to the opposing state due to
the slightest change in process condi-
tions Rapid and reliable indication of
this change of state is now available
Perhaps the most astonishingachievement in the power management
of two-wire loop-power flowmeters is
that of the ultrasonic biogas meter It is
now possible not only to measure the
flow of wet dirty variable composition
and low-pressure anaerobic digester
gas landfill gas and coal bed methane
gas with a two-wire loop-powered ultra-
sonic flowmeter but also the same de-
vice uses an inbuilt temperature sensor
in combination with measured sound
velocity to calculate methane contentcalorific value and energy flow
Technology to Take UsForwardModern flow technologies provide instru-
ment engineers with vital self-monitoring
information The format of such infor-
mation is easier to understand and act
upon when presented in accordance
with harmonized international guidelines
for online plant asset management eg
NAMUR Standard 107
Continuous plain-text self-diagnostic
and process-related information with
suggested remedies (Figure 3) make it
possible for instrument engineers andoperators to take action at the appro-
priate time mdash immediately or during
the next scheduled shutdown mdash saving
time and money by knowing the exact
health of their measuring point and the
probable actions required to rectify any
abnormal conditions Device verifica-
tion offering third-party validated trace-
ability can be performed on demand ei-
ther locally or remotely from the control
room without the expense of a man in
the field Calibration is then avoided ordeferred without process interruption
Where a process plant has a large
installed base of older mechanical tech-
nologies the decision to embark upon a
program of replacement for plant mod-
ernization cannot of course be taken
easily There are the stocks of spare
parts to consider along with the plant
instrument technicians who are trained
on and at ease with the old devices
However a process plant that retains
the older technology going forward willbe at risk and may find it increasingly
difficult or even impossible to maintain
a cost position that competes effective-
ly in the global market FC
wwwusendresscom
wwwflowcontrolnetworkcom January 2015 | 19
Steve Milford
is a Flow Product
Business Manager
for Endress+Hauser
Inc in Greenwood
Ind He has been
involved in flow
measurement since
1983 and has been
actively involved with standards devel-
opment for flow technology within the
International Standards Organization
(ISO) and the British Standards
Institute Mr Milford can be reached
at stevemilfordusendresscom
Steve Milford
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Coriolis Flowmeter | Magnetic Flowmeter | Two-Wire | Ultrasonic Flowmeter | Vortex Flowmeter
Figure 3 A modern instrumentrsquos display module can provide continuous plain- text self-diagnostic and process-related information
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2345
The bottom line is the volume of gas under one set of
pressure and temperature conditions is not the same as it
would be for the gas under different conditions Why is thisimportant Without compensation for compressibility read-
ings taken by gas flowmeters can result in measurementsmdash
and costs to the buyermdashsignificantly lower or higher than they
should be
The flow of gas in a system can be accounted for and
reported in a number of ways such as by volume by mass
flowrate and by energy Inline turbine meters can offer both
reliability and accuracy in measuring gas flow when matched
with a monitor capable of calculating and displaying results
that have been adjusted for the nature of the gas and impor-
tantly the pressure and temperature
Measuring Flow with an Inline TurbineFlowmeter
With an inline turbine meter gas flows into the meter through
a length of piping that helps to pre-condition the flow by
reducing undesirable swirls and asymmetry Where consid-
ered necessary a flow straightener may even be installed in
line to create a uniform flow profile to the extent possible
As can be seen in Figure 1 a rotor support within the tur-
bine housing further conditions the flow and directs it through
the blades of the rotor High-precision ball bearings allow the
rotor to freely rotate on the shaft
The rotorrsquos rotational speed is directly proportional to the velocity of the fluid passing through the meter The rotor itself
incorporates magnets (or magnetic blades depending on thedesign) while the housing is non-magnetic
A proximity sensor (also known as a pickup coil) is located
in line with the rotor and detects the electrical pulses gener-
ated by the ferrous rotor spinning through the magnetic field
Each pulse represents a discrete volume of gas The out-
put frequency provides the indication of the gas flow rate and
the accumulated pulses over a specified time represent the
total volume of fluid for that measurement period
Need for Calibration The flowrate of the gas through the meter cannot be deter-
mined accurately unless the meter is calibrated The fac-tory calibration determines the meterrsquos constant known
as a K-factor which is then inputted into the gas monitor
PPLICATION NOTES | Flow Measurement
20 | January 2015
Flow Control Magazine
COMPENSATING for
Compressibility inMeasuring Gas Flow Why K-factor adjustment is essential foraccurate inline turbine flow measurement
Unlike crude oil and other liquid fossilfuels natural gas poses a challenge
in monitoring the quantity of gas flowing
through pipelines While liquids do not com-
press gases do and the mass flowrate of
gas being transmitted through gathering
lines depends on both the pressure and
temperature
By Kevin Clark
Figure 1 Internal components of a liquid turbine flowmeter
C O U R T E S Y
T U R B I N E S
I N C
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2445
Wondering Whether the
Pump Guy Seminar
Is for YouCheck out the ldquoPump Guy Insightsrdquo
video series flwctrlcompginsights
PUMP GUY INSIGHT 1NPSHa vs NPSHrmdashWhy all pumps need gauges
PUMP GUY INSIGHT 3How to Operate Your Pump at Best Efficiency
PUMP GUY INSIGHT 5Head vs Flow
PUMP GUY INSIGHT 2 Your Pumps Are Constantly Moving On Their Curves
PUMP GUY INSIGHT 4 The Role of the Pump Reliability Chain
PUMP GUY INSIGHT 6How to Read a Pump Curve
PARTNER SPONSORSFor more information and to register
for upcoming Pump Guy Seminars
visit FlowControlNetworkcomPumpGuy
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2545
PPLICATION NOTES | Flow Measurement
22 | January 2015
Flow Control Magazine
Gas flowmeters measure the actual volume of gas passing
through the meter per minute irrespective of pressure and
temperature1
The volumetric flowrate of a gas is often corrected to
ldquostandardizedrdquo conditions of pressure and temperature While
ldquostandardrdquo conditions can vary depending on the definition
in the US this typically means a pressure of 1473 PSIA(pounds per square inch absolute) and a temperature of 60 F
The flowrate measurement is reported in standard cubic feet
per minute (SCFM)
Compensating for changes in pressure and temperature is
critical Consider a meter system setup for flowing conditions
of 60 PSIG (pounds per square inch gauge) and 60 F and the
line pressure decreases to 50 PSIG while the temperature
remains constant The difference in SCFM between the two
is more than 15 percent which would cost the buyer more
for the gas than it should As Table 1 demonstrates even a
small variation in pressure will result in a surprisingly high er-
ror percentage
Automation of the K-Factor The K-factor is established by an initial factory calibration In
the case of a non-compensated flow monitor any variations
in pressure and temperature will result in manual adjust-
ments needed to the K-factor In order to maintain accurate
flow measurement users must monitor pressure and temper-
ature and make corresponding adjustments to the K-factor To eliminate these manual adjustments some suppliers offer
a flow monitor that automatically adjusts for any changes in
pressure and temperature
These monitors provide accurate flow measurement regard-
less of changing environmental conditions in some cases sup-
porting applications with pressures as high as 15000 PSIG and
temperatures between -350 F to 350 F with a standard accura-
cy of +-1 percent over a flow range of 05 ACFM to 650 ACFM
Final NotesDuring the operation of a flowmeter system the ability to obtain
a readout mdash and to adjust for line pressure and temperaturechanges mdash is sometimes compromised by a lack of electric
power This issue is especially true along gas pipelines in remote
areas To overcome this limitation some manufacturers have
designed low-powered flow monitors which can operate for up
to on year on a single lithium D-cell battery
It is important for users to recognize the effects of the
compressibility of gas As such the quantity of a gas flow-
ing through a gas flowmeter depends on the pressure and
temperature In order to ensure accuracy any flowmetering
system must employ a means to correct for these effects
Otherwise the readout is certain to be in error and could be
unnecessarily costing money This is particularly crucial onwellhead production and in billing scenarios FC
wwwturbinesincorporatedcom
Notations1 The measurement factor in the US is known as the
ACFM actual cubic feet per minute (Metric units are typically
ACMH actual cubic meters per hour)
Table 1 Error induced by line pressure changes
Constant Temperature with Varying Pressure
Pressure Temperature PulsesSCF Error
50 60 2556027821 1546
51 60 2517123288 1370
52 60 2479385307 1199
53 60 2442762186 1034
54 60 240720524 873
55 60 237266858 717
56 60 2339108911 566
57 60 2306485356 418
58 60 2274759285 275
59 60 2243894166 136
60 60 2213855422 000
61 60 2184610304 132
62 60 2156127771 261
63 60 2128378378 386
64 60 210133418 508
65 60 2074968632 627
66 60 2049256506 743
67 60 2024173807 857
68 60 1999697703 967
69 60 1975806452 1075
70 60 1952479339 1181 Flow Measurement | K-Factor | Measurement
Accuracy | Turbine Flowmeter
Find related content flowcontrolnetworkcomhellipSearch on
FLOWSTREAM
Kevin Clark is senior develop-
ment engineer for Turbines Research
amp Development LLC Turbine RampD is a
subsidiary and the research and techni-
cal support arm of Turbines Inc which
serves a range of industries and applica-
tions from oil amp gas to cryogenic liquids
to custody transferKevin Clark
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2645
Pumps Bearings amp Seals TECHNOLOGY REPORT
FEATURES
SYSTEMS DESIGN
The ComplicatedCase of
Compressors
withSide-Streams
24 28 32BEST PRACTICES
How PumpingSystems
AffectSealing
Performance
TECH OUTLOOK
BearingSuppliers
Drive Gains InDeveloping
Markets
wwwflowcontrolnetworkcom January 2015 | 23
S P E C I AL S E C T I O N
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2745
The design and operation of compressors with side-
streams has always been difficult because flow entering the
compressor needs to be mixed with the core flow already
in the compressor (compressed in section-1) in a manner
that does not degrade the aerodynamic performance of sur-
rounding sections Minimizing losses and ensuring proper
mixing of the side-stream flow and core-flow are required to
ensure effective performance of a compressor of this sort
Key considerations for an application involving compres-
sors with side-stream flow include
The plant process typically dictates the side-stream
flange pressure
The impellers upstream of the side-stream should
achieve the necessary pressure for the core-flow
The side-stream flow is typically at a temperature dif-
ferent from compressor core-flow temperature
Process plants need some degree of operational flex-
ibility ie the ability to support variations in core-flow condi-
tions and side-stream conditions
Modern process plants are usually specifying more than
one operating conditions (sometimes two or more manda-
tory conditions) which can present challenges to compres-
sors with side-streams Adding to these issues modern
compressors should operate with much higher impeller tip
The COMPLICATED CASE ofCompressors with Side-StreamsConsidering key system design requirements
to ensure operational efficiency By Amin Almasi
4 January 2015
Flow Control Magazine
|
y
g
Some compressors in certain applications
have one or more incoming side-streams
(or side-loads) that introduce side-stream
flow to mix with the core flow In other words
a radial side-stream inlet is utilized in multi-
impeller centrifugal compressors to introduce
additional gas into the mid-stage of a com-
pressor This design enables optimization in
some process plants However the flow dis-
tribution after the junction of the side-stream
and the main return channel of the upstream
section can significantly affect the perfor-mance of the next section of compressor
In most cases the pressure levels at these
side-streams should be accurately predicted
to meet the theoretical performance
Compressor station at a natural gas processing plant
R U D M E R Z W E R V E R I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2845
speeds and inlet Mach numbers compared to previous
generations of compressor technology
Likewise side-streams are now com-
monly used with medium-sized and
large-sized compressors (eg 1ndash60
MW) The costs associated with cor-
rections on side-stream compres-
sor applicationsmdashany repair
inefficient operation and power
lossesmdashwould be very high Fur-
ther compressors with side-streams
are usually sensitive and difficult
machines to operate In particular
performance curves (performance
pressures efficiency etc) are sen-
sitive to suction inlet conditionsside-stream inlet conditions vol-
ume flow ratio (side-stream vol-
ume to core-flow volume) and side-stream losses
Compressors with side-stream often perform far below
expectations The main reason is that side-stream compres-
sors are different than conventional compressors (without
a side-stream) in design and operation For a compressor
with side-streams tighter tolerances in operating conditions
must be identified and applied Uncontrolled variations of
suction pressure or side-stream pressure are major prob-
lems Another major issue is the variations of the flow ratio
(side-stream flow to core-flow)
Compressor Side-Stream amp Mixing SectionIn many centrifugal compressors the portion of the side-
stream system from the flange connection to the mixing
section is similar to a compressor inlet A great challenge
is ensuring the mixing section provides circumferentially
uniform merged-flow with minimum losses This can be
achieved via effective design of the inlet configuration and
mixing section of the side-stream compressor such that
the impeller can be maintained over the whole operating
range of the compressor In many cases while there are
mixing sections provided for the machine the flows do not
completely mix before entering the impeller of the section-2
(the impeller after the mixing section) Non-uniformity at
inlet flow to the impeller is a key concern for compressor
performance
Another consideration is a compact design of the side-
stream mixing section Specifically a mixing section with
less axial length is always preferred This axial length can af-
fect the compressor rotor dynam-
ics the rotor length and over-
all compressor performance
(design cost operation and
reliability)
The side-stream exit pressure
(side-stream pressure at inlet
of the mixing section) is mainly
a function of the side-stream
flow velocity and the pres-
sure in the previous section of
the compressor Conversely the side-
stream flange pressure can depend on
side-stream flow velocity and section-1
exit conditions Therefore the side-stream
inlet flange volume flow is a function of theflange pressure compressibility (at that
pressure and temperature) and mass flow
Some engineers assume that the side-stream flange pres-
sure is equal to the inlet pressure of the first impeller of the
section-2 This is not true The mixed total pressure can be
estimated on a mass-averaged basis using side-stream total
pressure and return channel exit (section-1) total pressure
In some designs because of the lower static pressure at
the side-stream exit the total pressure at the return channel
exit is lower even though the velocity upstream is roughly
matched for both streams The pressure usually increased
at the returned channel but it can be reduced again at the
side-stream exit While simple in nature this can have an
impact on the prediction of pressure at the side-stream exit
and overall mixing section performance Based on basic flow
principles it was usually assumed that the static pressure
was equal between both flow streams at the mixing location
While this assumption might be used in rough calculations
the accurate simulations have shown this assumption is not
true In fact there are some points (for instance the shroud
wall at the exit of the return channel and the hub wall at
the exit of the side-stream) where this assumption is true
However this is not valid for all locations There are pressure
changes that occur from a side-stream flange to the inlet
of the next section (section-2) which depend on different
factors The first factor is the frictional losses due to side-
stream geometry from side-stream flange to plenum mix-
ing section etc The other factors are pressure changes due
to local curvature and geometry details of mixing section
Another consideration is the operation of a compressor
with side-stream at part-load The performance of the side-
wwwflowcontrolnetworkcom January 2015 25
Figure 1 An example of a centrifugalcompressor with side-stream
COURTESY SIEMENS
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 29456 January 2015
Flow Control Magazine
|
y
g
stream path the mixing section and
the downstream impellers when ma-
chine is operated at part-load or even
off-design operating flows will result
in additional compressor performance
problems In such a case both veloc-
ity profiles and pressure variations in
various parts (side-stream path mixing
section etc) will be different resulting
in complicated flow patterns and com-
plex aerodynamics behaviors
Side-Stream CompressorSectional Performance
Typically vendor-supplied compressor
performance curves reflect flange-to-flange performance because that is
what the plant engineers need to
evaluate the proper operation of their
system (for example from suction to
side-stream and from side-stream to
discharge) In many cases compres-
sor vendors also provide the over-
all compressor performance curves
and performance curves for section-1
(from suction to side-stream) and sec-
tion-2 (from side-stream to discharge)
Flange-to-flange data if not interpret-
ed properly can lead to false conclu-
sions about the relative performance
of individual sections of a compression
system For example if side-stream
losses from the flange to mixing sec-
tion are attributed to the downstream
section (section-2) it will cause the
downstream section (section-2) to
appear low in performance while the
upstream section (section-1) will show
high performance levels
An important behavior to con-
sider is when the actual side-stream
pressure is different than the rated
side-stream pressure When the side-
stream pressure is slightly higher than
the outlet pressure of the section-1
it (section-1) shows a relatively higher
performance compared to the real sec-
tion-1 performance In some cases
the performance of section-1 could be
considerably higher than section-2 In
other words when performance is de-
termined flange to flange the higher
flange pressure is seen as extra ldquopseu-
dordquo work done by the section (since this
is an inconsistent thermodynamic vol-
ume) resulting in a relatively high sec-
tional efficiency (section-1 shows a rel-
atively high efficiency) This is the case
for many compressors with side-stream
because the whole system is designed
(or specifically the side-stream location
is selected) in a way aimed at main-
taining the real side-stream pressure(side-stream inlet) above the section-1
outlet pressure because if the real side-
stream pressure becomes lower than
the section-1 outlet pressure the flow
may (theoretically) reverse
This is particularly important when
the side-stream mass flow is much
lower than the mass flow of core-flow
The above-mentioned reasons explain
why in many simulations calcula-
tions and performance reports related
to compressors with side-stream the
section-1 shows a relatively good ef-
ficiency and section-2 appears low in
efficiency
When the side-stream pressure is
slightly lower than the outlet pressure
of the section-1 the section-1 might
show a relatively lower performance
compared to section-2 This could oc-
cur in some recycle services where the
side-stream is actually a recycle flow
with a mass flow around two to five
times the core-flow The side-stream
(recycle) flow is returned from down-
stream of the compressor to be slightly
compressed and recycled to the down-
stream Such a recycled side-stream
compressor can present unique chal-
lenges for design and operation This
kind of machine usually needs very
special operating procedures and very
fine adjustments regarding operating
pressures and flows
Side-Stream Compressor
Performance amp Operation An important consideration is the sen-
sitivity of compressor overall perfor-
mance curve and sectional perfor-
mance curves to the flow ratio (ratio
of side-stream flow to core-flow) and
to the inlet conditions Variations in
the flow and pressure of the main
suction and side-stream inlet should
be controlled within tight tolerances
For compressors with side-stream the ASME PTC-10 code stipulates limits on
flow ratio (side-stream volume to core-
flow volume) The acceptable variation
in volume flow ratio in a compressor
with a side-stream is +-5 percent as
per ASME PTC code The requested
side-stream pressure tolerance is not
usually specified in compressor codes
but it should be around +- 2 percent
(or sometimes +- 25 percent)
Variance in flow ratio impacts the
velocity levels where the two streams
merge Significant variation in the ve-
locity profile upstream of the impeller
changes the incidence on the blade
leading edge of the following impel-
ler This change in incidence leads to a
change in sectional performance over-
all compressor performance and train
efficiency
If the flow ratio is varied between 95
percent and 105 percent (tolerances
specified in the ASME PTC-10 code)
the flange pressure changes accord-
ingly resulting in a change in the sec-
tional performance and overall perfor-
mance The sectional efficiency varies
sometimes more than +- 4 percent
This variance reduces as the flow is de-
creased toward surge However as the
flow is increased toward overload the
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3045wwwflowcontrolnetworkcom January 2015 27
variance increases up to higher values
(even in some cases three to five times
compared to variations near the surge
zone) For example in a case study
for a compressor with side-streams a
+- 5 percent variation in flow ratio and
associated changes (pressures losses
etc) the sectional efficiency reduced by
approximately 34 percent at the rated
flow at allowable operating points at
the end of curve (near the overload
ie choke) efficiency reduced by ap-
proximately 55 percent These results
show that the variation in sectional
performance and overall performance
due to flow ratio is highest at operat-ing points near the overload and low-
est at operating points near the surge
For compressors which work most of
the time at high flow (flow higher than
rated flow and discharge pressure low-
er than rated pressure) the effects of
flow ratio deviations (and subsequently
efficiency reduction) would be higher
than compressors working on the left-
hand side of curve (say with sufficient
margins near the surge)
In the compressor codes (such as
API 617) the compressor power varia-
tions should be maintained below 4
percent However in some applica-
tions clients require tighter tolerances
on the consumed power sometimes
below 2 percent (or even below 15
percent) Some studies suggest while
+- 5 percent of volume flow ratio is
suitable for performance test as per
ASME PTC-10 code some plants re-
quire tighter control on the consumed
power and compressor performance
(lower limits on the efficiency) the tol-
erances on the volume flow ratio could
be tighter than ASME PTC code In this
regard +- 4 percent tolerance can be
suggested on the volume flow ratio (ra-
tio of side-stream flow to core-flow) of
compressors with side-streams
Based on operational experiences
acceptable variations in volume flow
ratio and inlet pressures (suction inlet
and side-stream inlet) of a compressor
with side-streams are +- 4 percent
and +- 2 percent respectively
Another important consideration is
the required adjustments for the flow
ratio (side-stream flow to core-flow)
Compressors with side-stream usually
require fixed side-stream flange pres-
sures For a compressor with some variations in operation conditions (even
small changes) it is not usually pos-
sible to achieve optimum operation by
keeping the flow ratio (side-stream to
core-flow) constant The flow ratio has
to be adjusted according to the inlet
flow at which the machine is operating
in order to get the required correspond-
ing side-stream flange pressure
Thermal changes have also been
known to cause some instability in
centrifugal compressors An example is
the thermal-induced change of resid-
ual unbalance For compressors with
side-streams which feature tempera-
ture differences between core-flow and
side-stream flow the thermal behav-
ior of the compressor is usually more
complex and requires more attention
Heavy Gas ChallengeHeavy gases (such as heavy hydrocar-
bon gases eg propane propylene
MTBE (Methyl Tertiary Butyl Ether))
have very low gas sonic velocities that
produce high Mach numbers in the
aerodynamic flow paths For these
services because of high Mach num-
ber high flow coefficient stages have
very narrow flow maps characterized
by limited surge and choke margins
Compressors with side-streams in
these services present great challeng-
es This is to say the side-streams and
associated mixing further complicate
design operation and performance
prediction because the pressure tem-
perature and flow conditions at each
one of these side-streams as well
as at the exit of the machine require
stringent tolerances to optimize the
overall efficiency and performance
As such it is important to accuratelymodel design operate and moni-
tor performance characteristics of any
impellers diffusers return channels
and generally all flow-path components
in a compressor with side-stream FC
Amin Almasi
is a senior rotating
machine consultant
in Australia He is
a chartered profes- sional engineer of
Engineers Australia
(MIEAust CPEng ndash
Mechanical) and
IMechE (CEng MIMechE) holds
bachelorrsquos and masterrsquos degrees
in Mechanical Engineering and is
a registered professional engineer
in Queensland He specializes in
rotating machines including cen-
trifugal screw and reciprocating
compressors gas turbines steamturbines engines pumps subsea
offshore rotating machines LNG
units condition monitoring and reli-
ability Mr Almasi is an active mem-
ber of Engineers Australia IMechE
ASME and SPE He can be reached
at aminalmasiymailcom
Amin Almasi
Compressor | Gas Flow | Performance Curve | Side-Stream Flow
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3145
The pressure in the stuffing box
containing the packing can be estimat-
ed by the following equation
SBP = [Discharge ndash Suction] 3 + Suction
Pressure at the bottom of the stuff-
ing box will be higher than the suction
pressure but considerably lower than
the discharge pressure It should be
noted this calculation will yield a con-
servative estimate of stuffing box pres-
sure that can be further reduced by
pump design
A hole in the stuffing box serves as
a port for injecting clean fluid that cir-
culates around a lantern ring aligned
under the flush port The fluid flushes
solids back into the process to protect
the packing from abrasive wear If the
clean fluid is injected at a pressure ex-
ceeding that at the bottom of the stuff-
ing box some of it will leak back into
the process and some will leak out to
the atmosphere Recommended flush
injection pressure is 15ndash30 PSI (1ndash2
Bar) greater than the pressure at the
bottom of the stuffing box
Fluid injection is also used to lubri-
cate and cool dry-running packing that
is subject to frictional heat and to pre-
vent air from entering the pump which
reduces flow and operating efficiency
Centrifugal pumps utilize three
types of impellersmdashopen semi-open
and closed (Figures 2 3 amp 4) Open
designs prevent fluids with large solids
from clogging the impellers but at theexpense of pump efficiency Backing
plates on semi-open designs serve to
trap the fluid for more efficient opera-
tion Closed impellers are for use with
clean fluids since solids could ac-
cumulate in the eye which would re-
quire tearing down the pump to remove
them
Single-Stage CentrifugalPumpsSingle-stage centrifugal pumps typi-
cally have good bearing support of the
shaft with few run-out or ldquowhiprdquo prob-
lems However in some cases they
are subject to cavitation This occurs
in the eye of the impeller where the
fluid is under vacuum If the pressure
is low enough it will cause the material
to vaporize forming air or water vapor
bubbles As the fluid passes through
How Pumping Systems Design Affects Sealing Performance
By Chris Boss
8 January 2015
Flow Control Magazine
|
Understanding how different types of pump designs impact
sealing is critical to optimizing efficiency safety and lon-
gevity of the sealing system Used for a wide variety of media
including clear fluids solutions and slurries single-stage
centrifugal pumps are one of the most common
types (Figure 1) Fluid drawn into these pumps
enters the eye of an impeller that spins itto the outside of its container
or volute building pressure as
it moves toward discharge
Some of this fluid will work
its way behind the impeller
where it must be sealed with
compression packing or a
mechanical seal
Figure 1
Figure 2 Figure 3 Figure 4
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3245
the pump under increasing pressure
these bubbles implode sending shock
and vibration through the impeller
adversely affecting the seal This phe-
nomenon can be mitigated by running
the pump at slower speed and higher
pressure at the suction end to prevent
air from entering the fluid
Double-Ended Split-CasePumpsOperating on the same centrifugal prin-
ciple but slightly different geometry are
double-ended split-case pumps (Figure
5) Fluid enters both ends of the pump
and is directed into the eye of an impel-ler which spins it out of the volute to
discharge Packing is installed on both
the shaft and bearing ends so the stuff-
ing box is exposed only to suction pres-
sure which is usually quite low
Axial Flow Pumps Axial flow pumps operate like hydro
turbines in reverse whereby a propeller
(or axial impeller) pushes the fluid to
discharge (Figure 6)
Since the stuffing box is located
downstream of the propeller at the dis-
charge end of the pump the packing is
exposed to the full discharge pressure
Vertical PumpsVertical turbine pumps are typically
flange-mounted on a floor extending
downward into a water-filled sump
hole (Figure 7) Available as single- or
multi-stage pumps they feature an
impeller or series of impellers rotated
simultaneously by a single shaft The
impellers increase the pressure of the
upward flow subjecting the stuffing box
to full discharge pressure
Vertical pumps can be quite long so
inadequate bearing support can cause
the shaft to run out This can induce
undesirable lateral motion on the pack-
ing Worse the packing may be forced
to serve both as a bearing and a seal To
withstand these conditions the packing
should be resilient elastic and resistant
to deformation These properties rule
out packing such as graphite foil in favor
of fiber-based materials
Multi-Stage PumpsMulti-stage pumps are used for high-
pressure applications such as feeding
the boilers in steam-powered generating
plants Stuffing box pressure can vary
with pump design and number of stag-
es Designed for clean fluids and high
operating speeds these pumps typically
have high- and low-pressure ends with ahydraulic pressure equalization line run-
ning between the stuffing boxes
Like vertical pumps multi-stage
pumps feature a series of impellers to
build fluid discharge pressure In the
case of the six-stage pump pictured in
Figure 8 fluid enters at the drive end
where a stuffing box is exposed to suc-
tion pressure Channeled from one
impeller to the next through the pump
casting the fluid can reach extremely
high pressures at discharge
A second stuffing box located at the
bearing end is exposed to an intermedi-
ate pressure from the third impeller This
pressure is greater than the suction pres-
sure but much less than the discharge
pressure which can reach 2000 PSI
Fortunately the stuffing boxes in
these pumps are not exposed to dis-
charge pressures and typically see be-
low 500 PSI which is within the range
of some packing materials
wwwflowcontrolnetworkcom January 2015 29
Figure 5
Figure 6
Figure 7
Figure 8
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 33450 January 2015
Flow Control Magazine
| Gear PumpsPositive-displacement or gear pumps
operate on a different principle than
centrifugal pumps In external gear
pumps the fluid flows around the out-
side of the gears the intermeshing
of which forces it through the pump
to discharge (Figure 9) This design
makes these pumps particularly suit-
able for use with highly viscous fluids
such as resins emulsions syrups and
adhesives As such they are used for
transfer or metering applications
It should be noted gear pumps will
continue to displace fluid as long as
their shafts are turning which can pose
a problem if a clog occurs at the dis-
charge The resulting buildup of pres-
sure can blow out seals and damage
the pump Therefore most gear pumps
have pressure relief valves to divert
fluid back to the suction side for re-
circulation through the pump Internal
gear pumps operate slightly differently
but also have pressure relief valves to
prevent damage from excessive pres-
sure (Figure 10) In both external and
internal gear pumps the maximum
stuffing box pressure is determined by
these valves
Other rotating equipment includes
mixersagitators which are similar to
pumps in terms of the speeds to which
the packing is exposed There are ba-
sically three types of mixersagitators
top- bottom- and side-entry Top-entry
models are subject to the same con-
cerns about shaft run-out ldquowhiprdquo and
lateral forces on the paddles that are
encountered in some vertical pumps
Although some fluid may splash onto
the packing these mixers basically run
dry so the packing must have the abil-
ity to dissipate the resulting frictional
heat
In bottom-entry mixers the packing
is always exposed to fluid and may also
be exposed to solids requiring abra-
sion-resistance If the seal fails the en-
tire contents of the tank will eventually
drain out onto the bearings the floor
and other components under the stuff-
ing box
The packing in side-entry mixers may
be fully or intermittently exposed to flu-
id as well as side loading and vibration
Aside from media temperature
speed and other application variables
the configurations and operating prin-
ciples of rotary-type pumps exert differ-
ent forces on the seals used to keep
them from leaking These forces can
spell the difference between accept-
able seal performance and failure
Understanding these differences has
important implications that should be
taken into account to assure proper
sealing selection for long-term trou-
ble-free performance FC
wwwgarlockcom
Chris Boss is
a senior applica-
tions engineer for
Garlock Sealing
Technologies in
Palmyra NY He
has held various
positions in produc-
tion engineering
product development and applica-
tions engineering for the companyrsquos
compression packing division He
is a BSME graduate of the State
University of New York at Buffalo Mr
Boss can be reached at 800 448-
6688 or chrisbossgarlockcom
Chris Boss
Cavitation | Centrifugal Pump | Pump Packing | Sealing System
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Figure 9
Figure 10
Aside from media temperature speed and
other application variables the configurations
and operating principles of rotary-type
pumps exert different forces on the seals used
to keep them from leaking These forces can
spell the difference between acceptable seal
performance and failure
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3445
NS IDERNDUSTRIAL AUTOMATION + PROCESS CONTROL
WANT
INFORMATION
ON THE
automationindustry
SUBSCRIBE NOW at wwwiainsidercouk
Published by Spitzer and Boyes LLC Write in 15 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3545
Frost says the push from developing
economies is important as the market
is technologically mature and seeing
restricted growth in developed econo-
mies This is particularly true in Europe
and North America where recent finan-
cial insta-
bility has
reduced capital expenditure across end-
user industries
Bill Moore senior vice president of
sales development and channel man-
agement for global bearings manufac-
turer SKF says ldquosmartrdquo products and
the expansion of robust reliability pro-
grams are helping to drive new invest-
ment particularly in developed coun-
tries where the cost to compete is
high Frost says the magnitude of
the existing global installed base will
strengthen the need for replacement
and upgrades adding to market de-
mand as well
Frost says despite the potential
in developing economies the focus
on price as a product differentiator
may lead to intense price pressures
among manufacturers and bring down
the value of the overall market in the
short term The growing trend among
consumers to choose low-cost Chinese
imports will complicate this challenge
As price and quality become stan-
dardized across the globe customers
will base more of their purchasing deci-
sions on value-added services accord-
ing to Frost This will push manufactur-
ers to create more maintenance-free
solutions such as lubrication-free
bearings that offer end-users savings
on service and replacement costs and
reduce downtimeldquoOffering a complete line of prod-
ucts with comprehensive services will
be another feather in the cap of ven-
dors looking to widen their consumer
baserdquo notes Frost Industrial Automa-
tion and Process Control Research
Analyst Guru Mahesh
Moore says the trend of outsourcing
manufacturing to regions where labor
and production costs are favorable is
becoming less of a factor
ldquoThe days when cheap labor made
a significant difference in where a prod-
uct is manufactured mdash particularly high
value-added products or high weight
and bulk products mdash are coming to
an end as the cost of transportation
storage and inventory balance out the
benefits of production costs where la-
bor is a smaller percentage of the cost
of manufacturingrdquo Moore says ldquoLocal
manufacturing development will indeed
come to developing countries as their
ability to create markets that generate
economies of scale that support local
production is a clear trend and one that
all manufacturers will pay attention tordquo
Moore says that development of
maintenance-free or predictive tech-
nologies and products will be a sig-
nificant advantage to everyone in the
Bearing amp Coupling Manufacturers Focus
onDEVELOPING Economies
amp EFFICIENCY InnovationBy Amy W Richardson
2 January 2015
Flow Control Magazine
|
gy
Anew study from Frost amp Sullivan (wwwfrostcom) fore-
casts steady growth for the overall bearings and couplings
market based on rapid industrial development in high-growth
regions Specifically Frost predicts development in Mexico
Indonesia Nigeria Turkey Brazil Russia India and Chinawill help boost the bearings amp couplings market from $2206
billion in 2013 to an estimated $2676 billion in 2018
The development of maintenance-freeor predictive technologies will helpboost growth in the bearings market For example SKF is developing products that will automatically notifyusers when a bearing or mechanicalrotating component is approachingthe end of its useful life Pictured hereis an SKF Microlog analyzer a por- table condition monitoring tool
COURTESY SKF
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
improved productivity through simplified solutions The powerful technology and tools ensure repeatable
reliable accurate measurements Easier access to process data allows for better troubleshooting process
optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
For daily product notes visit the lsquoFeatured Productsrsquo section flowcontrolnetworkcom
ON THE WEB
1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3845
FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
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from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
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economical choices popular mod-
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wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
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eral capabilities inputsoutputs
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butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
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with its heavy-duty mixing
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chure details manufacturing
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wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
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CD The CD offers interactive
features including keyword
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print and page save in PDF
Also available for download is
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on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
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WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
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Brought to you by Beamex
Your Source For Fluid Handling Videos
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Select appropriate issue ofFlow Control Magazine
Select advertisements thatinterest you
Enter your email amp clickldquoSubmit Requestrdquo
1
2
3
4
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FEATURED VIDEO How to Calibrate aPressure Measurement Loop
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4245
THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
Name ________________________________________________________________
Title _________________________________________________________________
Company _____________________________________________________________
AddressCityStateZip __________________________________________________
______________________________________________________________________
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One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545
![Page 21: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/21.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 214518 | January 2015
Flow Control Magazine
porated into their new common electron-
ics platform in 2013 So all the ldquomodernrdquo
flow measurement technologies mdash that
is to say those introduced post-war mdash
have become available as two-wire loop-
powered devices with one exception
namely thermal mass (thermal disper-
sion) meters Unfortunately the power
requirements for this technology exceed
what is currently deemed possible withtwo-wire loop-power management
Payback forTechnology UpgradeConsider a 1rdquo process line
containing a liquid process
ingredient costing $1lb at a
mass flowrate of 150 lbmin-
ute We have $150minute
flowing in the line translating
to $9000hour and $72000
per eight-hour shift That cal-culates further to $360000
per five-day working week and
for a working year of 40 weeks for
example that is $144 million Assume
the existing device is a turbine flowmeter
Now imagine a two-wire loop-
powered Coriolis mass flowmeter is
installed in place of the existing meter
The line would need to be drained and
probably one process flange replaced
allowing the Coriolis to fit mechanically
in place of the turbine However thetwo-wire loop already used for carrying
the existing meterrsquos flow signal to the
control room can be used unaltered
for the complete electrical installation
aspects of the Coriolis flowmeter
The upside of the change is signifi-
cant and clear cut Assuming the exist-
ing meter measurement uncertainty was02 percent of reading then measure-
ment uncertainty improves through use
of Coriolis to 01 percent of reading
giving a 01100 x $14400000 im-
provement in control of the ingredient
annually or $14400 A two-wire Coriolis
mass flowmeter with 01 percent mass
flow accuracy would be paid for in ap-
proximately 6-8 months In practice the
improvement in measurement uncer-
tainty would be greater as the operator
would gain temperature and density in-formation from the Coriolis and the mea-
surement would be devoid of any fluid
property dependence Viscosity change
for example can have a major impact on
turbine meter performance Mechanical
wear and tear that turbine meters even-
tually experience which causes them to
under-register flow is precluded by mod-
ern devices like Coriolis
Furthermore if the process ingredient
was being blended with another then ad-
ditional process improvements could berealized through in-line blending control
using Coriolis technology for final density
as the control point It is possible to have
dual 4-20 mA outputs from two-wire
loop-powered meters but as the main
4-20 mA output representing the prima-
ry variable is also HART then an external
HART Loop Converter or HART IO card in
the control system can provide second-
ary tertiary and quaternary variables as
4-20 mA signals A Coriolis meter is trulya multi-variable device Certain two-wire
devices are also available with Profibus
or Foundation Fieldbus communication
Cutting Wiring CostsIn 2003 WIBEXERA (International
Instrument Usersrsquo Associations) Report
T 2732 X 03 was published and it pro- vided an average survey of prices quoted
in projects at that time for the provision
of power supplies for four-wire instru-
ments The price ranged from euro1200
to euro1800 per instrument depending
upon design and plant characteristics
for an average cost of euro1500 (about
$2000) It would be reasonable to
assume an inflationary factor of 2 per-
cent per annum giving an approximate
current-day figure of $2500
From another source within thechemical industry an estimation of
$40foot to $50foot was given for in-
stallation of four-wire cabling For a
linear 50-foot cable run with for ex-
ample a 10-foot vertical at each end
this equates to $3150 Actual costs
and budget estimates have been given
as high as $10000
The Extent of the Opportunity The modern post-war flow measure-
ment technologies have different powerrequirements and consequently they
are not all available for the
same size range in two-wire
loop-power form For example
two-wire Coriolis flowmeters
are limited to 2rdquo diameter
electromagnetic and inline
low-pressure gas ultrasonics
are limited to 8rdquo and vortex
and inline liquid ultrasonic are
limited to 12rdquo
Nevertheless for thechemical industry in particu-
lar perhaps two-thirds of the
process pipes in a plant will be no larger
than 2rdquo and even when the host process
pipe is larger a correctly sized flowmeter
can still be less than 2rdquo There is consid-
erable scope for two-wire loop-power to
deliver value for flow measurement ap-
plications with total safety
The virtues of Coriolis technology
have been covered but what about
other two-wire technologies An elec-tromagnetic flowmeter in two-wire form
YSTEMS DESIGN | Flow Measurement
In todayrsquos volatile global mar-
ketplace return on investment
calculations for plant upgrade or
new plant construction projects
may go through several itera-
tions before the trigger is finally
pulled or indeed not pulled
ldquo
rdquo
COURTESYENDRESS+HAUSER
Figure 2 Two-wire Coriolis flowme- ters became available in 2011
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2245
can be used on water wastewater or
a light water-based slurry provided the
fluid has around a 20 microSeimenscenti-
metre (microScm) electrical conductivity
A magnetic flowmeter is full bore un-
less flowrates dictate a reduced meter
size in the interests of performance and
so there are no intrusions into the flow
stream and no pressure loss An accu-
racy of 05 percent of reading is normal
from a two-wire magnetic meter and a
modest five diameters (5D) of straight in-let run is needed to avoid error from up-
stream flow disturbances When the fluid
exhibits insufficient conductivity then
the same performance and installation
requirements can be met by an inline ul-
trasonic flowmeter provided the liquid is
essentially clean and bubble-free
For gas or steam applications a vor-
tex meter is the normal choice Using a
built-in temperature sensor a two-wire
loop-powered vortex meter can calculate
mass flow of saturated steam using in-ternal steam tables An external pressure
input allows mass flow of steam to be ac-
curately calculated even when saturated
steam becomes superheated as can oc-
cur downstream of a pressure regulating
valve With mass flow known the vortex
meter can calculate energy and heat flow
A new and exciting development is
the ability of the vortex meter to indicate
wet steam and calculate dryness frac-
tion or steam quality For safety and ef-
ficiency saturated steam should be dry
and free from condensate that is to say
it should possess a high steam quality
factor However the dry or wet state of
saturated steam can sit on a knife-edge
and shift to the opposing state due to
the slightest change in process condi-
tions Rapid and reliable indication of
this change of state is now available
Perhaps the most astonishingachievement in the power management
of two-wire loop-power flowmeters is
that of the ultrasonic biogas meter It is
now possible not only to measure the
flow of wet dirty variable composition
and low-pressure anaerobic digester
gas landfill gas and coal bed methane
gas with a two-wire loop-powered ultra-
sonic flowmeter but also the same de-
vice uses an inbuilt temperature sensor
in combination with measured sound
velocity to calculate methane contentcalorific value and energy flow
Technology to Take UsForwardModern flow technologies provide instru-
ment engineers with vital self-monitoring
information The format of such infor-
mation is easier to understand and act
upon when presented in accordance
with harmonized international guidelines
for online plant asset management eg
NAMUR Standard 107
Continuous plain-text self-diagnostic
and process-related information with
suggested remedies (Figure 3) make it
possible for instrument engineers andoperators to take action at the appro-
priate time mdash immediately or during
the next scheduled shutdown mdash saving
time and money by knowing the exact
health of their measuring point and the
probable actions required to rectify any
abnormal conditions Device verifica-
tion offering third-party validated trace-
ability can be performed on demand ei-
ther locally or remotely from the control
room without the expense of a man in
the field Calibration is then avoided ordeferred without process interruption
Where a process plant has a large
installed base of older mechanical tech-
nologies the decision to embark upon a
program of replacement for plant mod-
ernization cannot of course be taken
easily There are the stocks of spare
parts to consider along with the plant
instrument technicians who are trained
on and at ease with the old devices
However a process plant that retains
the older technology going forward willbe at risk and may find it increasingly
difficult or even impossible to maintain
a cost position that competes effective-
ly in the global market FC
wwwusendresscom
wwwflowcontrolnetworkcom January 2015 | 19
Steve Milford
is a Flow Product
Business Manager
for Endress+Hauser
Inc in Greenwood
Ind He has been
involved in flow
measurement since
1983 and has been
actively involved with standards devel-
opment for flow technology within the
International Standards Organization
(ISO) and the British Standards
Institute Mr Milford can be reached
at stevemilfordusendresscom
Steve Milford
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Coriolis Flowmeter | Magnetic Flowmeter | Two-Wire | Ultrasonic Flowmeter | Vortex Flowmeter
Figure 3 A modern instrumentrsquos display module can provide continuous plain- text self-diagnostic and process-related information
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2345
The bottom line is the volume of gas under one set of
pressure and temperature conditions is not the same as it
would be for the gas under different conditions Why is thisimportant Without compensation for compressibility read-
ings taken by gas flowmeters can result in measurementsmdash
and costs to the buyermdashsignificantly lower or higher than they
should be
The flow of gas in a system can be accounted for and
reported in a number of ways such as by volume by mass
flowrate and by energy Inline turbine meters can offer both
reliability and accuracy in measuring gas flow when matched
with a monitor capable of calculating and displaying results
that have been adjusted for the nature of the gas and impor-
tantly the pressure and temperature
Measuring Flow with an Inline TurbineFlowmeter
With an inline turbine meter gas flows into the meter through
a length of piping that helps to pre-condition the flow by
reducing undesirable swirls and asymmetry Where consid-
ered necessary a flow straightener may even be installed in
line to create a uniform flow profile to the extent possible
As can be seen in Figure 1 a rotor support within the tur-
bine housing further conditions the flow and directs it through
the blades of the rotor High-precision ball bearings allow the
rotor to freely rotate on the shaft
The rotorrsquos rotational speed is directly proportional to the velocity of the fluid passing through the meter The rotor itself
incorporates magnets (or magnetic blades depending on thedesign) while the housing is non-magnetic
A proximity sensor (also known as a pickup coil) is located
in line with the rotor and detects the electrical pulses gener-
ated by the ferrous rotor spinning through the magnetic field
Each pulse represents a discrete volume of gas The out-
put frequency provides the indication of the gas flow rate and
the accumulated pulses over a specified time represent the
total volume of fluid for that measurement period
Need for Calibration The flowrate of the gas through the meter cannot be deter-
mined accurately unless the meter is calibrated The fac-tory calibration determines the meterrsquos constant known
as a K-factor which is then inputted into the gas monitor
PPLICATION NOTES | Flow Measurement
20 | January 2015
Flow Control Magazine
COMPENSATING for
Compressibility inMeasuring Gas Flow Why K-factor adjustment is essential foraccurate inline turbine flow measurement
Unlike crude oil and other liquid fossilfuels natural gas poses a challenge
in monitoring the quantity of gas flowing
through pipelines While liquids do not com-
press gases do and the mass flowrate of
gas being transmitted through gathering
lines depends on both the pressure and
temperature
By Kevin Clark
Figure 1 Internal components of a liquid turbine flowmeter
C O U R T E S Y
T U R B I N E S
I N C
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2445
Wondering Whether the
Pump Guy Seminar
Is for YouCheck out the ldquoPump Guy Insightsrdquo
video series flwctrlcompginsights
PUMP GUY INSIGHT 1NPSHa vs NPSHrmdashWhy all pumps need gauges
PUMP GUY INSIGHT 3How to Operate Your Pump at Best Efficiency
PUMP GUY INSIGHT 5Head vs Flow
PUMP GUY INSIGHT 2 Your Pumps Are Constantly Moving On Their Curves
PUMP GUY INSIGHT 4 The Role of the Pump Reliability Chain
PUMP GUY INSIGHT 6How to Read a Pump Curve
PARTNER SPONSORSFor more information and to register
for upcoming Pump Guy Seminars
visit FlowControlNetworkcomPumpGuy
7232019 Flow Control January 2015
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PPLICATION NOTES | Flow Measurement
22 | January 2015
Flow Control Magazine
Gas flowmeters measure the actual volume of gas passing
through the meter per minute irrespective of pressure and
temperature1
The volumetric flowrate of a gas is often corrected to
ldquostandardizedrdquo conditions of pressure and temperature While
ldquostandardrdquo conditions can vary depending on the definition
in the US this typically means a pressure of 1473 PSIA(pounds per square inch absolute) and a temperature of 60 F
The flowrate measurement is reported in standard cubic feet
per minute (SCFM)
Compensating for changes in pressure and temperature is
critical Consider a meter system setup for flowing conditions
of 60 PSIG (pounds per square inch gauge) and 60 F and the
line pressure decreases to 50 PSIG while the temperature
remains constant The difference in SCFM between the two
is more than 15 percent which would cost the buyer more
for the gas than it should As Table 1 demonstrates even a
small variation in pressure will result in a surprisingly high er-
ror percentage
Automation of the K-Factor The K-factor is established by an initial factory calibration In
the case of a non-compensated flow monitor any variations
in pressure and temperature will result in manual adjust-
ments needed to the K-factor In order to maintain accurate
flow measurement users must monitor pressure and temper-
ature and make corresponding adjustments to the K-factor To eliminate these manual adjustments some suppliers offer
a flow monitor that automatically adjusts for any changes in
pressure and temperature
These monitors provide accurate flow measurement regard-
less of changing environmental conditions in some cases sup-
porting applications with pressures as high as 15000 PSIG and
temperatures between -350 F to 350 F with a standard accura-
cy of +-1 percent over a flow range of 05 ACFM to 650 ACFM
Final NotesDuring the operation of a flowmeter system the ability to obtain
a readout mdash and to adjust for line pressure and temperaturechanges mdash is sometimes compromised by a lack of electric
power This issue is especially true along gas pipelines in remote
areas To overcome this limitation some manufacturers have
designed low-powered flow monitors which can operate for up
to on year on a single lithium D-cell battery
It is important for users to recognize the effects of the
compressibility of gas As such the quantity of a gas flow-
ing through a gas flowmeter depends on the pressure and
temperature In order to ensure accuracy any flowmetering
system must employ a means to correct for these effects
Otherwise the readout is certain to be in error and could be
unnecessarily costing money This is particularly crucial onwellhead production and in billing scenarios FC
wwwturbinesincorporatedcom
Notations1 The measurement factor in the US is known as the
ACFM actual cubic feet per minute (Metric units are typically
ACMH actual cubic meters per hour)
Table 1 Error induced by line pressure changes
Constant Temperature with Varying Pressure
Pressure Temperature PulsesSCF Error
50 60 2556027821 1546
51 60 2517123288 1370
52 60 2479385307 1199
53 60 2442762186 1034
54 60 240720524 873
55 60 237266858 717
56 60 2339108911 566
57 60 2306485356 418
58 60 2274759285 275
59 60 2243894166 136
60 60 2213855422 000
61 60 2184610304 132
62 60 2156127771 261
63 60 2128378378 386
64 60 210133418 508
65 60 2074968632 627
66 60 2049256506 743
67 60 2024173807 857
68 60 1999697703 967
69 60 1975806452 1075
70 60 1952479339 1181 Flow Measurement | K-Factor | Measurement
Accuracy | Turbine Flowmeter
Find related content flowcontrolnetworkcomhellipSearch on
FLOWSTREAM
Kevin Clark is senior develop-
ment engineer for Turbines Research
amp Development LLC Turbine RampD is a
subsidiary and the research and techni-
cal support arm of Turbines Inc which
serves a range of industries and applica-
tions from oil amp gas to cryogenic liquids
to custody transferKevin Clark
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2645
Pumps Bearings amp Seals TECHNOLOGY REPORT
FEATURES
SYSTEMS DESIGN
The ComplicatedCase of
Compressors
withSide-Streams
24 28 32BEST PRACTICES
How PumpingSystems
AffectSealing
Performance
TECH OUTLOOK
BearingSuppliers
Drive Gains InDeveloping
Markets
wwwflowcontrolnetworkcom January 2015 | 23
S P E C I AL S E C T I O N
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2745
The design and operation of compressors with side-
streams has always been difficult because flow entering the
compressor needs to be mixed with the core flow already
in the compressor (compressed in section-1) in a manner
that does not degrade the aerodynamic performance of sur-
rounding sections Minimizing losses and ensuring proper
mixing of the side-stream flow and core-flow are required to
ensure effective performance of a compressor of this sort
Key considerations for an application involving compres-
sors with side-stream flow include
The plant process typically dictates the side-stream
flange pressure
The impellers upstream of the side-stream should
achieve the necessary pressure for the core-flow
The side-stream flow is typically at a temperature dif-
ferent from compressor core-flow temperature
Process plants need some degree of operational flex-
ibility ie the ability to support variations in core-flow condi-
tions and side-stream conditions
Modern process plants are usually specifying more than
one operating conditions (sometimes two or more manda-
tory conditions) which can present challenges to compres-
sors with side-streams Adding to these issues modern
compressors should operate with much higher impeller tip
The COMPLICATED CASE ofCompressors with Side-StreamsConsidering key system design requirements
to ensure operational efficiency By Amin Almasi
4 January 2015
Flow Control Magazine
|
y
g
Some compressors in certain applications
have one or more incoming side-streams
(or side-loads) that introduce side-stream
flow to mix with the core flow In other words
a radial side-stream inlet is utilized in multi-
impeller centrifugal compressors to introduce
additional gas into the mid-stage of a com-
pressor This design enables optimization in
some process plants However the flow dis-
tribution after the junction of the side-stream
and the main return channel of the upstream
section can significantly affect the perfor-mance of the next section of compressor
In most cases the pressure levels at these
side-streams should be accurately predicted
to meet the theoretical performance
Compressor station at a natural gas processing plant
R U D M E R Z W E R V E R I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2845
speeds and inlet Mach numbers compared to previous
generations of compressor technology
Likewise side-streams are now com-
monly used with medium-sized and
large-sized compressors (eg 1ndash60
MW) The costs associated with cor-
rections on side-stream compres-
sor applicationsmdashany repair
inefficient operation and power
lossesmdashwould be very high Fur-
ther compressors with side-streams
are usually sensitive and difficult
machines to operate In particular
performance curves (performance
pressures efficiency etc) are sen-
sitive to suction inlet conditionsside-stream inlet conditions vol-
ume flow ratio (side-stream vol-
ume to core-flow volume) and side-stream losses
Compressors with side-stream often perform far below
expectations The main reason is that side-stream compres-
sors are different than conventional compressors (without
a side-stream) in design and operation For a compressor
with side-streams tighter tolerances in operating conditions
must be identified and applied Uncontrolled variations of
suction pressure or side-stream pressure are major prob-
lems Another major issue is the variations of the flow ratio
(side-stream flow to core-flow)
Compressor Side-Stream amp Mixing SectionIn many centrifugal compressors the portion of the side-
stream system from the flange connection to the mixing
section is similar to a compressor inlet A great challenge
is ensuring the mixing section provides circumferentially
uniform merged-flow with minimum losses This can be
achieved via effective design of the inlet configuration and
mixing section of the side-stream compressor such that
the impeller can be maintained over the whole operating
range of the compressor In many cases while there are
mixing sections provided for the machine the flows do not
completely mix before entering the impeller of the section-2
(the impeller after the mixing section) Non-uniformity at
inlet flow to the impeller is a key concern for compressor
performance
Another consideration is a compact design of the side-
stream mixing section Specifically a mixing section with
less axial length is always preferred This axial length can af-
fect the compressor rotor dynam-
ics the rotor length and over-
all compressor performance
(design cost operation and
reliability)
The side-stream exit pressure
(side-stream pressure at inlet
of the mixing section) is mainly
a function of the side-stream
flow velocity and the pres-
sure in the previous section of
the compressor Conversely the side-
stream flange pressure can depend on
side-stream flow velocity and section-1
exit conditions Therefore the side-stream
inlet flange volume flow is a function of theflange pressure compressibility (at that
pressure and temperature) and mass flow
Some engineers assume that the side-stream flange pres-
sure is equal to the inlet pressure of the first impeller of the
section-2 This is not true The mixed total pressure can be
estimated on a mass-averaged basis using side-stream total
pressure and return channel exit (section-1) total pressure
In some designs because of the lower static pressure at
the side-stream exit the total pressure at the return channel
exit is lower even though the velocity upstream is roughly
matched for both streams The pressure usually increased
at the returned channel but it can be reduced again at the
side-stream exit While simple in nature this can have an
impact on the prediction of pressure at the side-stream exit
and overall mixing section performance Based on basic flow
principles it was usually assumed that the static pressure
was equal between both flow streams at the mixing location
While this assumption might be used in rough calculations
the accurate simulations have shown this assumption is not
true In fact there are some points (for instance the shroud
wall at the exit of the return channel and the hub wall at
the exit of the side-stream) where this assumption is true
However this is not valid for all locations There are pressure
changes that occur from a side-stream flange to the inlet
of the next section (section-2) which depend on different
factors The first factor is the frictional losses due to side-
stream geometry from side-stream flange to plenum mix-
ing section etc The other factors are pressure changes due
to local curvature and geometry details of mixing section
Another consideration is the operation of a compressor
with side-stream at part-load The performance of the side-
wwwflowcontrolnetworkcom January 2015 25
Figure 1 An example of a centrifugalcompressor with side-stream
COURTESY SIEMENS
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 29456 January 2015
Flow Control Magazine
|
y
g
stream path the mixing section and
the downstream impellers when ma-
chine is operated at part-load or even
off-design operating flows will result
in additional compressor performance
problems In such a case both veloc-
ity profiles and pressure variations in
various parts (side-stream path mixing
section etc) will be different resulting
in complicated flow patterns and com-
plex aerodynamics behaviors
Side-Stream CompressorSectional Performance
Typically vendor-supplied compressor
performance curves reflect flange-to-flange performance because that is
what the plant engineers need to
evaluate the proper operation of their
system (for example from suction to
side-stream and from side-stream to
discharge) In many cases compres-
sor vendors also provide the over-
all compressor performance curves
and performance curves for section-1
(from suction to side-stream) and sec-
tion-2 (from side-stream to discharge)
Flange-to-flange data if not interpret-
ed properly can lead to false conclu-
sions about the relative performance
of individual sections of a compression
system For example if side-stream
losses from the flange to mixing sec-
tion are attributed to the downstream
section (section-2) it will cause the
downstream section (section-2) to
appear low in performance while the
upstream section (section-1) will show
high performance levels
An important behavior to con-
sider is when the actual side-stream
pressure is different than the rated
side-stream pressure When the side-
stream pressure is slightly higher than
the outlet pressure of the section-1
it (section-1) shows a relatively higher
performance compared to the real sec-
tion-1 performance In some cases
the performance of section-1 could be
considerably higher than section-2 In
other words when performance is de-
termined flange to flange the higher
flange pressure is seen as extra ldquopseu-
dordquo work done by the section (since this
is an inconsistent thermodynamic vol-
ume) resulting in a relatively high sec-
tional efficiency (section-1 shows a rel-
atively high efficiency) This is the case
for many compressors with side-stream
because the whole system is designed
(or specifically the side-stream location
is selected) in a way aimed at main-
taining the real side-stream pressure(side-stream inlet) above the section-1
outlet pressure because if the real side-
stream pressure becomes lower than
the section-1 outlet pressure the flow
may (theoretically) reverse
This is particularly important when
the side-stream mass flow is much
lower than the mass flow of core-flow
The above-mentioned reasons explain
why in many simulations calcula-
tions and performance reports related
to compressors with side-stream the
section-1 shows a relatively good ef-
ficiency and section-2 appears low in
efficiency
When the side-stream pressure is
slightly lower than the outlet pressure
of the section-1 the section-1 might
show a relatively lower performance
compared to section-2 This could oc-
cur in some recycle services where the
side-stream is actually a recycle flow
with a mass flow around two to five
times the core-flow The side-stream
(recycle) flow is returned from down-
stream of the compressor to be slightly
compressed and recycled to the down-
stream Such a recycled side-stream
compressor can present unique chal-
lenges for design and operation This
kind of machine usually needs very
special operating procedures and very
fine adjustments regarding operating
pressures and flows
Side-Stream Compressor
Performance amp Operation An important consideration is the sen-
sitivity of compressor overall perfor-
mance curve and sectional perfor-
mance curves to the flow ratio (ratio
of side-stream flow to core-flow) and
to the inlet conditions Variations in
the flow and pressure of the main
suction and side-stream inlet should
be controlled within tight tolerances
For compressors with side-stream the ASME PTC-10 code stipulates limits on
flow ratio (side-stream volume to core-
flow volume) The acceptable variation
in volume flow ratio in a compressor
with a side-stream is +-5 percent as
per ASME PTC code The requested
side-stream pressure tolerance is not
usually specified in compressor codes
but it should be around +- 2 percent
(or sometimes +- 25 percent)
Variance in flow ratio impacts the
velocity levels where the two streams
merge Significant variation in the ve-
locity profile upstream of the impeller
changes the incidence on the blade
leading edge of the following impel-
ler This change in incidence leads to a
change in sectional performance over-
all compressor performance and train
efficiency
If the flow ratio is varied between 95
percent and 105 percent (tolerances
specified in the ASME PTC-10 code)
the flange pressure changes accord-
ingly resulting in a change in the sec-
tional performance and overall perfor-
mance The sectional efficiency varies
sometimes more than +- 4 percent
This variance reduces as the flow is de-
creased toward surge However as the
flow is increased toward overload the
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3045wwwflowcontrolnetworkcom January 2015 27
variance increases up to higher values
(even in some cases three to five times
compared to variations near the surge
zone) For example in a case study
for a compressor with side-streams a
+- 5 percent variation in flow ratio and
associated changes (pressures losses
etc) the sectional efficiency reduced by
approximately 34 percent at the rated
flow at allowable operating points at
the end of curve (near the overload
ie choke) efficiency reduced by ap-
proximately 55 percent These results
show that the variation in sectional
performance and overall performance
due to flow ratio is highest at operat-ing points near the overload and low-
est at operating points near the surge
For compressors which work most of
the time at high flow (flow higher than
rated flow and discharge pressure low-
er than rated pressure) the effects of
flow ratio deviations (and subsequently
efficiency reduction) would be higher
than compressors working on the left-
hand side of curve (say with sufficient
margins near the surge)
In the compressor codes (such as
API 617) the compressor power varia-
tions should be maintained below 4
percent However in some applica-
tions clients require tighter tolerances
on the consumed power sometimes
below 2 percent (or even below 15
percent) Some studies suggest while
+- 5 percent of volume flow ratio is
suitable for performance test as per
ASME PTC-10 code some plants re-
quire tighter control on the consumed
power and compressor performance
(lower limits on the efficiency) the tol-
erances on the volume flow ratio could
be tighter than ASME PTC code In this
regard +- 4 percent tolerance can be
suggested on the volume flow ratio (ra-
tio of side-stream flow to core-flow) of
compressors with side-streams
Based on operational experiences
acceptable variations in volume flow
ratio and inlet pressures (suction inlet
and side-stream inlet) of a compressor
with side-streams are +- 4 percent
and +- 2 percent respectively
Another important consideration is
the required adjustments for the flow
ratio (side-stream flow to core-flow)
Compressors with side-stream usually
require fixed side-stream flange pres-
sures For a compressor with some variations in operation conditions (even
small changes) it is not usually pos-
sible to achieve optimum operation by
keeping the flow ratio (side-stream to
core-flow) constant The flow ratio has
to be adjusted according to the inlet
flow at which the machine is operating
in order to get the required correspond-
ing side-stream flange pressure
Thermal changes have also been
known to cause some instability in
centrifugal compressors An example is
the thermal-induced change of resid-
ual unbalance For compressors with
side-streams which feature tempera-
ture differences between core-flow and
side-stream flow the thermal behav-
ior of the compressor is usually more
complex and requires more attention
Heavy Gas ChallengeHeavy gases (such as heavy hydrocar-
bon gases eg propane propylene
MTBE (Methyl Tertiary Butyl Ether))
have very low gas sonic velocities that
produce high Mach numbers in the
aerodynamic flow paths For these
services because of high Mach num-
ber high flow coefficient stages have
very narrow flow maps characterized
by limited surge and choke margins
Compressors with side-streams in
these services present great challeng-
es This is to say the side-streams and
associated mixing further complicate
design operation and performance
prediction because the pressure tem-
perature and flow conditions at each
one of these side-streams as well
as at the exit of the machine require
stringent tolerances to optimize the
overall efficiency and performance
As such it is important to accuratelymodel design operate and moni-
tor performance characteristics of any
impellers diffusers return channels
and generally all flow-path components
in a compressor with side-stream FC
Amin Almasi
is a senior rotating
machine consultant
in Australia He is
a chartered profes- sional engineer of
Engineers Australia
(MIEAust CPEng ndash
Mechanical) and
IMechE (CEng MIMechE) holds
bachelorrsquos and masterrsquos degrees
in Mechanical Engineering and is
a registered professional engineer
in Queensland He specializes in
rotating machines including cen-
trifugal screw and reciprocating
compressors gas turbines steamturbines engines pumps subsea
offshore rotating machines LNG
units condition monitoring and reli-
ability Mr Almasi is an active mem-
ber of Engineers Australia IMechE
ASME and SPE He can be reached
at aminalmasiymailcom
Amin Almasi
Compressor | Gas Flow | Performance Curve | Side-Stream Flow
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3145
The pressure in the stuffing box
containing the packing can be estimat-
ed by the following equation
SBP = [Discharge ndash Suction] 3 + Suction
Pressure at the bottom of the stuff-
ing box will be higher than the suction
pressure but considerably lower than
the discharge pressure It should be
noted this calculation will yield a con-
servative estimate of stuffing box pres-
sure that can be further reduced by
pump design
A hole in the stuffing box serves as
a port for injecting clean fluid that cir-
culates around a lantern ring aligned
under the flush port The fluid flushes
solids back into the process to protect
the packing from abrasive wear If the
clean fluid is injected at a pressure ex-
ceeding that at the bottom of the stuff-
ing box some of it will leak back into
the process and some will leak out to
the atmosphere Recommended flush
injection pressure is 15ndash30 PSI (1ndash2
Bar) greater than the pressure at the
bottom of the stuffing box
Fluid injection is also used to lubri-
cate and cool dry-running packing that
is subject to frictional heat and to pre-
vent air from entering the pump which
reduces flow and operating efficiency
Centrifugal pumps utilize three
types of impellersmdashopen semi-open
and closed (Figures 2 3 amp 4) Open
designs prevent fluids with large solids
from clogging the impellers but at theexpense of pump efficiency Backing
plates on semi-open designs serve to
trap the fluid for more efficient opera-
tion Closed impellers are for use with
clean fluids since solids could ac-
cumulate in the eye which would re-
quire tearing down the pump to remove
them
Single-Stage CentrifugalPumpsSingle-stage centrifugal pumps typi-
cally have good bearing support of the
shaft with few run-out or ldquowhiprdquo prob-
lems However in some cases they
are subject to cavitation This occurs
in the eye of the impeller where the
fluid is under vacuum If the pressure
is low enough it will cause the material
to vaporize forming air or water vapor
bubbles As the fluid passes through
How Pumping Systems Design Affects Sealing Performance
By Chris Boss
8 January 2015
Flow Control Magazine
|
Understanding how different types of pump designs impact
sealing is critical to optimizing efficiency safety and lon-
gevity of the sealing system Used for a wide variety of media
including clear fluids solutions and slurries single-stage
centrifugal pumps are one of the most common
types (Figure 1) Fluid drawn into these pumps
enters the eye of an impeller that spins itto the outside of its container
or volute building pressure as
it moves toward discharge
Some of this fluid will work
its way behind the impeller
where it must be sealed with
compression packing or a
mechanical seal
Figure 1
Figure 2 Figure 3 Figure 4
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3245
the pump under increasing pressure
these bubbles implode sending shock
and vibration through the impeller
adversely affecting the seal This phe-
nomenon can be mitigated by running
the pump at slower speed and higher
pressure at the suction end to prevent
air from entering the fluid
Double-Ended Split-CasePumpsOperating on the same centrifugal prin-
ciple but slightly different geometry are
double-ended split-case pumps (Figure
5) Fluid enters both ends of the pump
and is directed into the eye of an impel-ler which spins it out of the volute to
discharge Packing is installed on both
the shaft and bearing ends so the stuff-
ing box is exposed only to suction pres-
sure which is usually quite low
Axial Flow Pumps Axial flow pumps operate like hydro
turbines in reverse whereby a propeller
(or axial impeller) pushes the fluid to
discharge (Figure 6)
Since the stuffing box is located
downstream of the propeller at the dis-
charge end of the pump the packing is
exposed to the full discharge pressure
Vertical PumpsVertical turbine pumps are typically
flange-mounted on a floor extending
downward into a water-filled sump
hole (Figure 7) Available as single- or
multi-stage pumps they feature an
impeller or series of impellers rotated
simultaneously by a single shaft The
impellers increase the pressure of the
upward flow subjecting the stuffing box
to full discharge pressure
Vertical pumps can be quite long so
inadequate bearing support can cause
the shaft to run out This can induce
undesirable lateral motion on the pack-
ing Worse the packing may be forced
to serve both as a bearing and a seal To
withstand these conditions the packing
should be resilient elastic and resistant
to deformation These properties rule
out packing such as graphite foil in favor
of fiber-based materials
Multi-Stage PumpsMulti-stage pumps are used for high-
pressure applications such as feeding
the boilers in steam-powered generating
plants Stuffing box pressure can vary
with pump design and number of stag-
es Designed for clean fluids and high
operating speeds these pumps typically
have high- and low-pressure ends with ahydraulic pressure equalization line run-
ning between the stuffing boxes
Like vertical pumps multi-stage
pumps feature a series of impellers to
build fluid discharge pressure In the
case of the six-stage pump pictured in
Figure 8 fluid enters at the drive end
where a stuffing box is exposed to suc-
tion pressure Channeled from one
impeller to the next through the pump
casting the fluid can reach extremely
high pressures at discharge
A second stuffing box located at the
bearing end is exposed to an intermedi-
ate pressure from the third impeller This
pressure is greater than the suction pres-
sure but much less than the discharge
pressure which can reach 2000 PSI
Fortunately the stuffing boxes in
these pumps are not exposed to dis-
charge pressures and typically see be-
low 500 PSI which is within the range
of some packing materials
wwwflowcontrolnetworkcom January 2015 29
Figure 5
Figure 6
Figure 7
Figure 8
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 33450 January 2015
Flow Control Magazine
| Gear PumpsPositive-displacement or gear pumps
operate on a different principle than
centrifugal pumps In external gear
pumps the fluid flows around the out-
side of the gears the intermeshing
of which forces it through the pump
to discharge (Figure 9) This design
makes these pumps particularly suit-
able for use with highly viscous fluids
such as resins emulsions syrups and
adhesives As such they are used for
transfer or metering applications
It should be noted gear pumps will
continue to displace fluid as long as
their shafts are turning which can pose
a problem if a clog occurs at the dis-
charge The resulting buildup of pres-
sure can blow out seals and damage
the pump Therefore most gear pumps
have pressure relief valves to divert
fluid back to the suction side for re-
circulation through the pump Internal
gear pumps operate slightly differently
but also have pressure relief valves to
prevent damage from excessive pres-
sure (Figure 10) In both external and
internal gear pumps the maximum
stuffing box pressure is determined by
these valves
Other rotating equipment includes
mixersagitators which are similar to
pumps in terms of the speeds to which
the packing is exposed There are ba-
sically three types of mixersagitators
top- bottom- and side-entry Top-entry
models are subject to the same con-
cerns about shaft run-out ldquowhiprdquo and
lateral forces on the paddles that are
encountered in some vertical pumps
Although some fluid may splash onto
the packing these mixers basically run
dry so the packing must have the abil-
ity to dissipate the resulting frictional
heat
In bottom-entry mixers the packing
is always exposed to fluid and may also
be exposed to solids requiring abra-
sion-resistance If the seal fails the en-
tire contents of the tank will eventually
drain out onto the bearings the floor
and other components under the stuff-
ing box
The packing in side-entry mixers may
be fully or intermittently exposed to flu-
id as well as side loading and vibration
Aside from media temperature
speed and other application variables
the configurations and operating prin-
ciples of rotary-type pumps exert differ-
ent forces on the seals used to keep
them from leaking These forces can
spell the difference between accept-
able seal performance and failure
Understanding these differences has
important implications that should be
taken into account to assure proper
sealing selection for long-term trou-
ble-free performance FC
wwwgarlockcom
Chris Boss is
a senior applica-
tions engineer for
Garlock Sealing
Technologies in
Palmyra NY He
has held various
positions in produc-
tion engineering
product development and applica-
tions engineering for the companyrsquos
compression packing division He
is a BSME graduate of the State
University of New York at Buffalo Mr
Boss can be reached at 800 448-
6688 or chrisbossgarlockcom
Chris Boss
Cavitation | Centrifugal Pump | Pump Packing | Sealing System
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Figure 9
Figure 10
Aside from media temperature speed and
other application variables the configurations
and operating principles of rotary-type
pumps exert different forces on the seals used
to keep them from leaking These forces can
spell the difference between acceptable seal
performance and failure
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3445
NS IDERNDUSTRIAL AUTOMATION + PROCESS CONTROL
WANT
INFORMATION
ON THE
automationindustry
SUBSCRIBE NOW at wwwiainsidercouk
Published by Spitzer and Boyes LLC Write in 15 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
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Frost says the push from developing
economies is important as the market
is technologically mature and seeing
restricted growth in developed econo-
mies This is particularly true in Europe
and North America where recent finan-
cial insta-
bility has
reduced capital expenditure across end-
user industries
Bill Moore senior vice president of
sales development and channel man-
agement for global bearings manufac-
turer SKF says ldquosmartrdquo products and
the expansion of robust reliability pro-
grams are helping to drive new invest-
ment particularly in developed coun-
tries where the cost to compete is
high Frost says the magnitude of
the existing global installed base will
strengthen the need for replacement
and upgrades adding to market de-
mand as well
Frost says despite the potential
in developing economies the focus
on price as a product differentiator
may lead to intense price pressures
among manufacturers and bring down
the value of the overall market in the
short term The growing trend among
consumers to choose low-cost Chinese
imports will complicate this challenge
As price and quality become stan-
dardized across the globe customers
will base more of their purchasing deci-
sions on value-added services accord-
ing to Frost This will push manufactur-
ers to create more maintenance-free
solutions such as lubrication-free
bearings that offer end-users savings
on service and replacement costs and
reduce downtimeldquoOffering a complete line of prod-
ucts with comprehensive services will
be another feather in the cap of ven-
dors looking to widen their consumer
baserdquo notes Frost Industrial Automa-
tion and Process Control Research
Analyst Guru Mahesh
Moore says the trend of outsourcing
manufacturing to regions where labor
and production costs are favorable is
becoming less of a factor
ldquoThe days when cheap labor made
a significant difference in where a prod-
uct is manufactured mdash particularly high
value-added products or high weight
and bulk products mdash are coming to
an end as the cost of transportation
storage and inventory balance out the
benefits of production costs where la-
bor is a smaller percentage of the cost
of manufacturingrdquo Moore says ldquoLocal
manufacturing development will indeed
come to developing countries as their
ability to create markets that generate
economies of scale that support local
production is a clear trend and one that
all manufacturers will pay attention tordquo
Moore says that development of
maintenance-free or predictive tech-
nologies and products will be a sig-
nificant advantage to everyone in the
Bearing amp Coupling Manufacturers Focus
onDEVELOPING Economies
amp EFFICIENCY InnovationBy Amy W Richardson
2 January 2015
Flow Control Magazine
|
gy
Anew study from Frost amp Sullivan (wwwfrostcom) fore-
casts steady growth for the overall bearings and couplings
market based on rapid industrial development in high-growth
regions Specifically Frost predicts development in Mexico
Indonesia Nigeria Turkey Brazil Russia India and Chinawill help boost the bearings amp couplings market from $2206
billion in 2013 to an estimated $2676 billion in 2018
The development of maintenance-freeor predictive technologies will helpboost growth in the bearings market For example SKF is developing products that will automatically notifyusers when a bearing or mechanicalrotating component is approachingthe end of its useful life Pictured hereis an SKF Microlog analyzer a por- table condition monitoring tool
COURTESY SKF
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
improved productivity through simplified solutions The powerful technology and tools ensure repeatable
reliable accurate measurements Easier access to process data allows for better troubleshooting process
optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
For daily product notes visit the lsquoFeatured Productsrsquo section flowcontrolnetworkcom
ON THE WEB
1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
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FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
and benefits as well as grids of
instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
services provided for the
mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
Brought to you by Beamex
Your Source For Fluid Handling Videos
Go towwwflowcontrolnetworkcomfreeinfo
Select appropriate issue ofFlow Control Magazine
Select advertisements thatinterest you
Enter your email amp clickldquoSubmit Requestrdquo
1
2
3
4
PRODUCT
INFORMATION
ONLINE
Follow these 4 steps to receive freeproduct information from suppliers
FREE
FEATURED VIDEO How to Calibrate aPressure Measurement Loop
For more information about FlowTube
sponsor packs email FlowControlGrandViewMediacom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4245
THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
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Title _________________________________________________________________
Company _____________________________________________________________
AddressCityStateZip __________________________________________________
______________________________________________________________________
Phone ________________________________________________________________
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One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545
![Page 22: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/22.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2245
can be used on water wastewater or
a light water-based slurry provided the
fluid has around a 20 microSeimenscenti-
metre (microScm) electrical conductivity
A magnetic flowmeter is full bore un-
less flowrates dictate a reduced meter
size in the interests of performance and
so there are no intrusions into the flow
stream and no pressure loss An accu-
racy of 05 percent of reading is normal
from a two-wire magnetic meter and a
modest five diameters (5D) of straight in-let run is needed to avoid error from up-
stream flow disturbances When the fluid
exhibits insufficient conductivity then
the same performance and installation
requirements can be met by an inline ul-
trasonic flowmeter provided the liquid is
essentially clean and bubble-free
For gas or steam applications a vor-
tex meter is the normal choice Using a
built-in temperature sensor a two-wire
loop-powered vortex meter can calculate
mass flow of saturated steam using in-ternal steam tables An external pressure
input allows mass flow of steam to be ac-
curately calculated even when saturated
steam becomes superheated as can oc-
cur downstream of a pressure regulating
valve With mass flow known the vortex
meter can calculate energy and heat flow
A new and exciting development is
the ability of the vortex meter to indicate
wet steam and calculate dryness frac-
tion or steam quality For safety and ef-
ficiency saturated steam should be dry
and free from condensate that is to say
it should possess a high steam quality
factor However the dry or wet state of
saturated steam can sit on a knife-edge
and shift to the opposing state due to
the slightest change in process condi-
tions Rapid and reliable indication of
this change of state is now available
Perhaps the most astonishingachievement in the power management
of two-wire loop-power flowmeters is
that of the ultrasonic biogas meter It is
now possible not only to measure the
flow of wet dirty variable composition
and low-pressure anaerobic digester
gas landfill gas and coal bed methane
gas with a two-wire loop-powered ultra-
sonic flowmeter but also the same de-
vice uses an inbuilt temperature sensor
in combination with measured sound
velocity to calculate methane contentcalorific value and energy flow
Technology to Take UsForwardModern flow technologies provide instru-
ment engineers with vital self-monitoring
information The format of such infor-
mation is easier to understand and act
upon when presented in accordance
with harmonized international guidelines
for online plant asset management eg
NAMUR Standard 107
Continuous plain-text self-diagnostic
and process-related information with
suggested remedies (Figure 3) make it
possible for instrument engineers andoperators to take action at the appro-
priate time mdash immediately or during
the next scheduled shutdown mdash saving
time and money by knowing the exact
health of their measuring point and the
probable actions required to rectify any
abnormal conditions Device verifica-
tion offering third-party validated trace-
ability can be performed on demand ei-
ther locally or remotely from the control
room without the expense of a man in
the field Calibration is then avoided ordeferred without process interruption
Where a process plant has a large
installed base of older mechanical tech-
nologies the decision to embark upon a
program of replacement for plant mod-
ernization cannot of course be taken
easily There are the stocks of spare
parts to consider along with the plant
instrument technicians who are trained
on and at ease with the old devices
However a process plant that retains
the older technology going forward willbe at risk and may find it increasingly
difficult or even impossible to maintain
a cost position that competes effective-
ly in the global market FC
wwwusendresscom
wwwflowcontrolnetworkcom January 2015 | 19
Steve Milford
is a Flow Product
Business Manager
for Endress+Hauser
Inc in Greenwood
Ind He has been
involved in flow
measurement since
1983 and has been
actively involved with standards devel-
opment for flow technology within the
International Standards Organization
(ISO) and the British Standards
Institute Mr Milford can be reached
at stevemilfordusendresscom
Steve Milford
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Coriolis Flowmeter | Magnetic Flowmeter | Two-Wire | Ultrasonic Flowmeter | Vortex Flowmeter
Figure 3 A modern instrumentrsquos display module can provide continuous plain- text self-diagnostic and process-related information
C O U R T E S Y E N D R E S S + H A U S E R
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2345
The bottom line is the volume of gas under one set of
pressure and temperature conditions is not the same as it
would be for the gas under different conditions Why is thisimportant Without compensation for compressibility read-
ings taken by gas flowmeters can result in measurementsmdash
and costs to the buyermdashsignificantly lower or higher than they
should be
The flow of gas in a system can be accounted for and
reported in a number of ways such as by volume by mass
flowrate and by energy Inline turbine meters can offer both
reliability and accuracy in measuring gas flow when matched
with a monitor capable of calculating and displaying results
that have been adjusted for the nature of the gas and impor-
tantly the pressure and temperature
Measuring Flow with an Inline TurbineFlowmeter
With an inline turbine meter gas flows into the meter through
a length of piping that helps to pre-condition the flow by
reducing undesirable swirls and asymmetry Where consid-
ered necessary a flow straightener may even be installed in
line to create a uniform flow profile to the extent possible
As can be seen in Figure 1 a rotor support within the tur-
bine housing further conditions the flow and directs it through
the blades of the rotor High-precision ball bearings allow the
rotor to freely rotate on the shaft
The rotorrsquos rotational speed is directly proportional to the velocity of the fluid passing through the meter The rotor itself
incorporates magnets (or magnetic blades depending on thedesign) while the housing is non-magnetic
A proximity sensor (also known as a pickup coil) is located
in line with the rotor and detects the electrical pulses gener-
ated by the ferrous rotor spinning through the magnetic field
Each pulse represents a discrete volume of gas The out-
put frequency provides the indication of the gas flow rate and
the accumulated pulses over a specified time represent the
total volume of fluid for that measurement period
Need for Calibration The flowrate of the gas through the meter cannot be deter-
mined accurately unless the meter is calibrated The fac-tory calibration determines the meterrsquos constant known
as a K-factor which is then inputted into the gas monitor
PPLICATION NOTES | Flow Measurement
20 | January 2015
Flow Control Magazine
COMPENSATING for
Compressibility inMeasuring Gas Flow Why K-factor adjustment is essential foraccurate inline turbine flow measurement
Unlike crude oil and other liquid fossilfuels natural gas poses a challenge
in monitoring the quantity of gas flowing
through pipelines While liquids do not com-
press gases do and the mass flowrate of
gas being transmitted through gathering
lines depends on both the pressure and
temperature
By Kevin Clark
Figure 1 Internal components of a liquid turbine flowmeter
C O U R T E S Y
T U R B I N E S
I N C
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2445
Wondering Whether the
Pump Guy Seminar
Is for YouCheck out the ldquoPump Guy Insightsrdquo
video series flwctrlcompginsights
PUMP GUY INSIGHT 1NPSHa vs NPSHrmdashWhy all pumps need gauges
PUMP GUY INSIGHT 3How to Operate Your Pump at Best Efficiency
PUMP GUY INSIGHT 5Head vs Flow
PUMP GUY INSIGHT 2 Your Pumps Are Constantly Moving On Their Curves
PUMP GUY INSIGHT 4 The Role of the Pump Reliability Chain
PUMP GUY INSIGHT 6How to Read a Pump Curve
PARTNER SPONSORSFor more information and to register
for upcoming Pump Guy Seminars
visit FlowControlNetworkcomPumpGuy
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2545
PPLICATION NOTES | Flow Measurement
22 | January 2015
Flow Control Magazine
Gas flowmeters measure the actual volume of gas passing
through the meter per minute irrespective of pressure and
temperature1
The volumetric flowrate of a gas is often corrected to
ldquostandardizedrdquo conditions of pressure and temperature While
ldquostandardrdquo conditions can vary depending on the definition
in the US this typically means a pressure of 1473 PSIA(pounds per square inch absolute) and a temperature of 60 F
The flowrate measurement is reported in standard cubic feet
per minute (SCFM)
Compensating for changes in pressure and temperature is
critical Consider a meter system setup for flowing conditions
of 60 PSIG (pounds per square inch gauge) and 60 F and the
line pressure decreases to 50 PSIG while the temperature
remains constant The difference in SCFM between the two
is more than 15 percent which would cost the buyer more
for the gas than it should As Table 1 demonstrates even a
small variation in pressure will result in a surprisingly high er-
ror percentage
Automation of the K-Factor The K-factor is established by an initial factory calibration In
the case of a non-compensated flow monitor any variations
in pressure and temperature will result in manual adjust-
ments needed to the K-factor In order to maintain accurate
flow measurement users must monitor pressure and temper-
ature and make corresponding adjustments to the K-factor To eliminate these manual adjustments some suppliers offer
a flow monitor that automatically adjusts for any changes in
pressure and temperature
These monitors provide accurate flow measurement regard-
less of changing environmental conditions in some cases sup-
porting applications with pressures as high as 15000 PSIG and
temperatures between -350 F to 350 F with a standard accura-
cy of +-1 percent over a flow range of 05 ACFM to 650 ACFM
Final NotesDuring the operation of a flowmeter system the ability to obtain
a readout mdash and to adjust for line pressure and temperaturechanges mdash is sometimes compromised by a lack of electric
power This issue is especially true along gas pipelines in remote
areas To overcome this limitation some manufacturers have
designed low-powered flow monitors which can operate for up
to on year on a single lithium D-cell battery
It is important for users to recognize the effects of the
compressibility of gas As such the quantity of a gas flow-
ing through a gas flowmeter depends on the pressure and
temperature In order to ensure accuracy any flowmetering
system must employ a means to correct for these effects
Otherwise the readout is certain to be in error and could be
unnecessarily costing money This is particularly crucial onwellhead production and in billing scenarios FC
wwwturbinesincorporatedcom
Notations1 The measurement factor in the US is known as the
ACFM actual cubic feet per minute (Metric units are typically
ACMH actual cubic meters per hour)
Table 1 Error induced by line pressure changes
Constant Temperature with Varying Pressure
Pressure Temperature PulsesSCF Error
50 60 2556027821 1546
51 60 2517123288 1370
52 60 2479385307 1199
53 60 2442762186 1034
54 60 240720524 873
55 60 237266858 717
56 60 2339108911 566
57 60 2306485356 418
58 60 2274759285 275
59 60 2243894166 136
60 60 2213855422 000
61 60 2184610304 132
62 60 2156127771 261
63 60 2128378378 386
64 60 210133418 508
65 60 2074968632 627
66 60 2049256506 743
67 60 2024173807 857
68 60 1999697703 967
69 60 1975806452 1075
70 60 1952479339 1181 Flow Measurement | K-Factor | Measurement
Accuracy | Turbine Flowmeter
Find related content flowcontrolnetworkcomhellipSearch on
FLOWSTREAM
Kevin Clark is senior develop-
ment engineer for Turbines Research
amp Development LLC Turbine RampD is a
subsidiary and the research and techni-
cal support arm of Turbines Inc which
serves a range of industries and applica-
tions from oil amp gas to cryogenic liquids
to custody transferKevin Clark
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2645
Pumps Bearings amp Seals TECHNOLOGY REPORT
FEATURES
SYSTEMS DESIGN
The ComplicatedCase of
Compressors
withSide-Streams
24 28 32BEST PRACTICES
How PumpingSystems
AffectSealing
Performance
TECH OUTLOOK
BearingSuppliers
Drive Gains InDeveloping
Markets
wwwflowcontrolnetworkcom January 2015 | 23
S P E C I AL S E C T I O N
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2745
The design and operation of compressors with side-
streams has always been difficult because flow entering the
compressor needs to be mixed with the core flow already
in the compressor (compressed in section-1) in a manner
that does not degrade the aerodynamic performance of sur-
rounding sections Minimizing losses and ensuring proper
mixing of the side-stream flow and core-flow are required to
ensure effective performance of a compressor of this sort
Key considerations for an application involving compres-
sors with side-stream flow include
The plant process typically dictates the side-stream
flange pressure
The impellers upstream of the side-stream should
achieve the necessary pressure for the core-flow
The side-stream flow is typically at a temperature dif-
ferent from compressor core-flow temperature
Process plants need some degree of operational flex-
ibility ie the ability to support variations in core-flow condi-
tions and side-stream conditions
Modern process plants are usually specifying more than
one operating conditions (sometimes two or more manda-
tory conditions) which can present challenges to compres-
sors with side-streams Adding to these issues modern
compressors should operate with much higher impeller tip
The COMPLICATED CASE ofCompressors with Side-StreamsConsidering key system design requirements
to ensure operational efficiency By Amin Almasi
4 January 2015
Flow Control Magazine
|
y
g
Some compressors in certain applications
have one or more incoming side-streams
(or side-loads) that introduce side-stream
flow to mix with the core flow In other words
a radial side-stream inlet is utilized in multi-
impeller centrifugal compressors to introduce
additional gas into the mid-stage of a com-
pressor This design enables optimization in
some process plants However the flow dis-
tribution after the junction of the side-stream
and the main return channel of the upstream
section can significantly affect the perfor-mance of the next section of compressor
In most cases the pressure levels at these
side-streams should be accurately predicted
to meet the theoretical performance
Compressor station at a natural gas processing plant
R U D M E R Z W E R V E R I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2845
speeds and inlet Mach numbers compared to previous
generations of compressor technology
Likewise side-streams are now com-
monly used with medium-sized and
large-sized compressors (eg 1ndash60
MW) The costs associated with cor-
rections on side-stream compres-
sor applicationsmdashany repair
inefficient operation and power
lossesmdashwould be very high Fur-
ther compressors with side-streams
are usually sensitive and difficult
machines to operate In particular
performance curves (performance
pressures efficiency etc) are sen-
sitive to suction inlet conditionsside-stream inlet conditions vol-
ume flow ratio (side-stream vol-
ume to core-flow volume) and side-stream losses
Compressors with side-stream often perform far below
expectations The main reason is that side-stream compres-
sors are different than conventional compressors (without
a side-stream) in design and operation For a compressor
with side-streams tighter tolerances in operating conditions
must be identified and applied Uncontrolled variations of
suction pressure or side-stream pressure are major prob-
lems Another major issue is the variations of the flow ratio
(side-stream flow to core-flow)
Compressor Side-Stream amp Mixing SectionIn many centrifugal compressors the portion of the side-
stream system from the flange connection to the mixing
section is similar to a compressor inlet A great challenge
is ensuring the mixing section provides circumferentially
uniform merged-flow with minimum losses This can be
achieved via effective design of the inlet configuration and
mixing section of the side-stream compressor such that
the impeller can be maintained over the whole operating
range of the compressor In many cases while there are
mixing sections provided for the machine the flows do not
completely mix before entering the impeller of the section-2
(the impeller after the mixing section) Non-uniformity at
inlet flow to the impeller is a key concern for compressor
performance
Another consideration is a compact design of the side-
stream mixing section Specifically a mixing section with
less axial length is always preferred This axial length can af-
fect the compressor rotor dynam-
ics the rotor length and over-
all compressor performance
(design cost operation and
reliability)
The side-stream exit pressure
(side-stream pressure at inlet
of the mixing section) is mainly
a function of the side-stream
flow velocity and the pres-
sure in the previous section of
the compressor Conversely the side-
stream flange pressure can depend on
side-stream flow velocity and section-1
exit conditions Therefore the side-stream
inlet flange volume flow is a function of theflange pressure compressibility (at that
pressure and temperature) and mass flow
Some engineers assume that the side-stream flange pres-
sure is equal to the inlet pressure of the first impeller of the
section-2 This is not true The mixed total pressure can be
estimated on a mass-averaged basis using side-stream total
pressure and return channel exit (section-1) total pressure
In some designs because of the lower static pressure at
the side-stream exit the total pressure at the return channel
exit is lower even though the velocity upstream is roughly
matched for both streams The pressure usually increased
at the returned channel but it can be reduced again at the
side-stream exit While simple in nature this can have an
impact on the prediction of pressure at the side-stream exit
and overall mixing section performance Based on basic flow
principles it was usually assumed that the static pressure
was equal between both flow streams at the mixing location
While this assumption might be used in rough calculations
the accurate simulations have shown this assumption is not
true In fact there are some points (for instance the shroud
wall at the exit of the return channel and the hub wall at
the exit of the side-stream) where this assumption is true
However this is not valid for all locations There are pressure
changes that occur from a side-stream flange to the inlet
of the next section (section-2) which depend on different
factors The first factor is the frictional losses due to side-
stream geometry from side-stream flange to plenum mix-
ing section etc The other factors are pressure changes due
to local curvature and geometry details of mixing section
Another consideration is the operation of a compressor
with side-stream at part-load The performance of the side-
wwwflowcontrolnetworkcom January 2015 25
Figure 1 An example of a centrifugalcompressor with side-stream
COURTESY SIEMENS
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 29456 January 2015
Flow Control Magazine
|
y
g
stream path the mixing section and
the downstream impellers when ma-
chine is operated at part-load or even
off-design operating flows will result
in additional compressor performance
problems In such a case both veloc-
ity profiles and pressure variations in
various parts (side-stream path mixing
section etc) will be different resulting
in complicated flow patterns and com-
plex aerodynamics behaviors
Side-Stream CompressorSectional Performance
Typically vendor-supplied compressor
performance curves reflect flange-to-flange performance because that is
what the plant engineers need to
evaluate the proper operation of their
system (for example from suction to
side-stream and from side-stream to
discharge) In many cases compres-
sor vendors also provide the over-
all compressor performance curves
and performance curves for section-1
(from suction to side-stream) and sec-
tion-2 (from side-stream to discharge)
Flange-to-flange data if not interpret-
ed properly can lead to false conclu-
sions about the relative performance
of individual sections of a compression
system For example if side-stream
losses from the flange to mixing sec-
tion are attributed to the downstream
section (section-2) it will cause the
downstream section (section-2) to
appear low in performance while the
upstream section (section-1) will show
high performance levels
An important behavior to con-
sider is when the actual side-stream
pressure is different than the rated
side-stream pressure When the side-
stream pressure is slightly higher than
the outlet pressure of the section-1
it (section-1) shows a relatively higher
performance compared to the real sec-
tion-1 performance In some cases
the performance of section-1 could be
considerably higher than section-2 In
other words when performance is de-
termined flange to flange the higher
flange pressure is seen as extra ldquopseu-
dordquo work done by the section (since this
is an inconsistent thermodynamic vol-
ume) resulting in a relatively high sec-
tional efficiency (section-1 shows a rel-
atively high efficiency) This is the case
for many compressors with side-stream
because the whole system is designed
(or specifically the side-stream location
is selected) in a way aimed at main-
taining the real side-stream pressure(side-stream inlet) above the section-1
outlet pressure because if the real side-
stream pressure becomes lower than
the section-1 outlet pressure the flow
may (theoretically) reverse
This is particularly important when
the side-stream mass flow is much
lower than the mass flow of core-flow
The above-mentioned reasons explain
why in many simulations calcula-
tions and performance reports related
to compressors with side-stream the
section-1 shows a relatively good ef-
ficiency and section-2 appears low in
efficiency
When the side-stream pressure is
slightly lower than the outlet pressure
of the section-1 the section-1 might
show a relatively lower performance
compared to section-2 This could oc-
cur in some recycle services where the
side-stream is actually a recycle flow
with a mass flow around two to five
times the core-flow The side-stream
(recycle) flow is returned from down-
stream of the compressor to be slightly
compressed and recycled to the down-
stream Such a recycled side-stream
compressor can present unique chal-
lenges for design and operation This
kind of machine usually needs very
special operating procedures and very
fine adjustments regarding operating
pressures and flows
Side-Stream Compressor
Performance amp Operation An important consideration is the sen-
sitivity of compressor overall perfor-
mance curve and sectional perfor-
mance curves to the flow ratio (ratio
of side-stream flow to core-flow) and
to the inlet conditions Variations in
the flow and pressure of the main
suction and side-stream inlet should
be controlled within tight tolerances
For compressors with side-stream the ASME PTC-10 code stipulates limits on
flow ratio (side-stream volume to core-
flow volume) The acceptable variation
in volume flow ratio in a compressor
with a side-stream is +-5 percent as
per ASME PTC code The requested
side-stream pressure tolerance is not
usually specified in compressor codes
but it should be around +- 2 percent
(or sometimes +- 25 percent)
Variance in flow ratio impacts the
velocity levels where the two streams
merge Significant variation in the ve-
locity profile upstream of the impeller
changes the incidence on the blade
leading edge of the following impel-
ler This change in incidence leads to a
change in sectional performance over-
all compressor performance and train
efficiency
If the flow ratio is varied between 95
percent and 105 percent (tolerances
specified in the ASME PTC-10 code)
the flange pressure changes accord-
ingly resulting in a change in the sec-
tional performance and overall perfor-
mance The sectional efficiency varies
sometimes more than +- 4 percent
This variance reduces as the flow is de-
creased toward surge However as the
flow is increased toward overload the
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3045wwwflowcontrolnetworkcom January 2015 27
variance increases up to higher values
(even in some cases three to five times
compared to variations near the surge
zone) For example in a case study
for a compressor with side-streams a
+- 5 percent variation in flow ratio and
associated changes (pressures losses
etc) the sectional efficiency reduced by
approximately 34 percent at the rated
flow at allowable operating points at
the end of curve (near the overload
ie choke) efficiency reduced by ap-
proximately 55 percent These results
show that the variation in sectional
performance and overall performance
due to flow ratio is highest at operat-ing points near the overload and low-
est at operating points near the surge
For compressors which work most of
the time at high flow (flow higher than
rated flow and discharge pressure low-
er than rated pressure) the effects of
flow ratio deviations (and subsequently
efficiency reduction) would be higher
than compressors working on the left-
hand side of curve (say with sufficient
margins near the surge)
In the compressor codes (such as
API 617) the compressor power varia-
tions should be maintained below 4
percent However in some applica-
tions clients require tighter tolerances
on the consumed power sometimes
below 2 percent (or even below 15
percent) Some studies suggest while
+- 5 percent of volume flow ratio is
suitable for performance test as per
ASME PTC-10 code some plants re-
quire tighter control on the consumed
power and compressor performance
(lower limits on the efficiency) the tol-
erances on the volume flow ratio could
be tighter than ASME PTC code In this
regard +- 4 percent tolerance can be
suggested on the volume flow ratio (ra-
tio of side-stream flow to core-flow) of
compressors with side-streams
Based on operational experiences
acceptable variations in volume flow
ratio and inlet pressures (suction inlet
and side-stream inlet) of a compressor
with side-streams are +- 4 percent
and +- 2 percent respectively
Another important consideration is
the required adjustments for the flow
ratio (side-stream flow to core-flow)
Compressors with side-stream usually
require fixed side-stream flange pres-
sures For a compressor with some variations in operation conditions (even
small changes) it is not usually pos-
sible to achieve optimum operation by
keeping the flow ratio (side-stream to
core-flow) constant The flow ratio has
to be adjusted according to the inlet
flow at which the machine is operating
in order to get the required correspond-
ing side-stream flange pressure
Thermal changes have also been
known to cause some instability in
centrifugal compressors An example is
the thermal-induced change of resid-
ual unbalance For compressors with
side-streams which feature tempera-
ture differences between core-flow and
side-stream flow the thermal behav-
ior of the compressor is usually more
complex and requires more attention
Heavy Gas ChallengeHeavy gases (such as heavy hydrocar-
bon gases eg propane propylene
MTBE (Methyl Tertiary Butyl Ether))
have very low gas sonic velocities that
produce high Mach numbers in the
aerodynamic flow paths For these
services because of high Mach num-
ber high flow coefficient stages have
very narrow flow maps characterized
by limited surge and choke margins
Compressors with side-streams in
these services present great challeng-
es This is to say the side-streams and
associated mixing further complicate
design operation and performance
prediction because the pressure tem-
perature and flow conditions at each
one of these side-streams as well
as at the exit of the machine require
stringent tolerances to optimize the
overall efficiency and performance
As such it is important to accuratelymodel design operate and moni-
tor performance characteristics of any
impellers diffusers return channels
and generally all flow-path components
in a compressor with side-stream FC
Amin Almasi
is a senior rotating
machine consultant
in Australia He is
a chartered profes- sional engineer of
Engineers Australia
(MIEAust CPEng ndash
Mechanical) and
IMechE (CEng MIMechE) holds
bachelorrsquos and masterrsquos degrees
in Mechanical Engineering and is
a registered professional engineer
in Queensland He specializes in
rotating machines including cen-
trifugal screw and reciprocating
compressors gas turbines steamturbines engines pumps subsea
offshore rotating machines LNG
units condition monitoring and reli-
ability Mr Almasi is an active mem-
ber of Engineers Australia IMechE
ASME and SPE He can be reached
at aminalmasiymailcom
Amin Almasi
Compressor | Gas Flow | Performance Curve | Side-Stream Flow
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3145
The pressure in the stuffing box
containing the packing can be estimat-
ed by the following equation
SBP = [Discharge ndash Suction] 3 + Suction
Pressure at the bottom of the stuff-
ing box will be higher than the suction
pressure but considerably lower than
the discharge pressure It should be
noted this calculation will yield a con-
servative estimate of stuffing box pres-
sure that can be further reduced by
pump design
A hole in the stuffing box serves as
a port for injecting clean fluid that cir-
culates around a lantern ring aligned
under the flush port The fluid flushes
solids back into the process to protect
the packing from abrasive wear If the
clean fluid is injected at a pressure ex-
ceeding that at the bottom of the stuff-
ing box some of it will leak back into
the process and some will leak out to
the atmosphere Recommended flush
injection pressure is 15ndash30 PSI (1ndash2
Bar) greater than the pressure at the
bottom of the stuffing box
Fluid injection is also used to lubri-
cate and cool dry-running packing that
is subject to frictional heat and to pre-
vent air from entering the pump which
reduces flow and operating efficiency
Centrifugal pumps utilize three
types of impellersmdashopen semi-open
and closed (Figures 2 3 amp 4) Open
designs prevent fluids with large solids
from clogging the impellers but at theexpense of pump efficiency Backing
plates on semi-open designs serve to
trap the fluid for more efficient opera-
tion Closed impellers are for use with
clean fluids since solids could ac-
cumulate in the eye which would re-
quire tearing down the pump to remove
them
Single-Stage CentrifugalPumpsSingle-stage centrifugal pumps typi-
cally have good bearing support of the
shaft with few run-out or ldquowhiprdquo prob-
lems However in some cases they
are subject to cavitation This occurs
in the eye of the impeller where the
fluid is under vacuum If the pressure
is low enough it will cause the material
to vaporize forming air or water vapor
bubbles As the fluid passes through
How Pumping Systems Design Affects Sealing Performance
By Chris Boss
8 January 2015
Flow Control Magazine
|
Understanding how different types of pump designs impact
sealing is critical to optimizing efficiency safety and lon-
gevity of the sealing system Used for a wide variety of media
including clear fluids solutions and slurries single-stage
centrifugal pumps are one of the most common
types (Figure 1) Fluid drawn into these pumps
enters the eye of an impeller that spins itto the outside of its container
or volute building pressure as
it moves toward discharge
Some of this fluid will work
its way behind the impeller
where it must be sealed with
compression packing or a
mechanical seal
Figure 1
Figure 2 Figure 3 Figure 4
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3245
the pump under increasing pressure
these bubbles implode sending shock
and vibration through the impeller
adversely affecting the seal This phe-
nomenon can be mitigated by running
the pump at slower speed and higher
pressure at the suction end to prevent
air from entering the fluid
Double-Ended Split-CasePumpsOperating on the same centrifugal prin-
ciple but slightly different geometry are
double-ended split-case pumps (Figure
5) Fluid enters both ends of the pump
and is directed into the eye of an impel-ler which spins it out of the volute to
discharge Packing is installed on both
the shaft and bearing ends so the stuff-
ing box is exposed only to suction pres-
sure which is usually quite low
Axial Flow Pumps Axial flow pumps operate like hydro
turbines in reverse whereby a propeller
(or axial impeller) pushes the fluid to
discharge (Figure 6)
Since the stuffing box is located
downstream of the propeller at the dis-
charge end of the pump the packing is
exposed to the full discharge pressure
Vertical PumpsVertical turbine pumps are typically
flange-mounted on a floor extending
downward into a water-filled sump
hole (Figure 7) Available as single- or
multi-stage pumps they feature an
impeller or series of impellers rotated
simultaneously by a single shaft The
impellers increase the pressure of the
upward flow subjecting the stuffing box
to full discharge pressure
Vertical pumps can be quite long so
inadequate bearing support can cause
the shaft to run out This can induce
undesirable lateral motion on the pack-
ing Worse the packing may be forced
to serve both as a bearing and a seal To
withstand these conditions the packing
should be resilient elastic and resistant
to deformation These properties rule
out packing such as graphite foil in favor
of fiber-based materials
Multi-Stage PumpsMulti-stage pumps are used for high-
pressure applications such as feeding
the boilers in steam-powered generating
plants Stuffing box pressure can vary
with pump design and number of stag-
es Designed for clean fluids and high
operating speeds these pumps typically
have high- and low-pressure ends with ahydraulic pressure equalization line run-
ning between the stuffing boxes
Like vertical pumps multi-stage
pumps feature a series of impellers to
build fluid discharge pressure In the
case of the six-stage pump pictured in
Figure 8 fluid enters at the drive end
where a stuffing box is exposed to suc-
tion pressure Channeled from one
impeller to the next through the pump
casting the fluid can reach extremely
high pressures at discharge
A second stuffing box located at the
bearing end is exposed to an intermedi-
ate pressure from the third impeller This
pressure is greater than the suction pres-
sure but much less than the discharge
pressure which can reach 2000 PSI
Fortunately the stuffing boxes in
these pumps are not exposed to dis-
charge pressures and typically see be-
low 500 PSI which is within the range
of some packing materials
wwwflowcontrolnetworkcom January 2015 29
Figure 5
Figure 6
Figure 7
Figure 8
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 33450 January 2015
Flow Control Magazine
| Gear PumpsPositive-displacement or gear pumps
operate on a different principle than
centrifugal pumps In external gear
pumps the fluid flows around the out-
side of the gears the intermeshing
of which forces it through the pump
to discharge (Figure 9) This design
makes these pumps particularly suit-
able for use with highly viscous fluids
such as resins emulsions syrups and
adhesives As such they are used for
transfer or metering applications
It should be noted gear pumps will
continue to displace fluid as long as
their shafts are turning which can pose
a problem if a clog occurs at the dis-
charge The resulting buildup of pres-
sure can blow out seals and damage
the pump Therefore most gear pumps
have pressure relief valves to divert
fluid back to the suction side for re-
circulation through the pump Internal
gear pumps operate slightly differently
but also have pressure relief valves to
prevent damage from excessive pres-
sure (Figure 10) In both external and
internal gear pumps the maximum
stuffing box pressure is determined by
these valves
Other rotating equipment includes
mixersagitators which are similar to
pumps in terms of the speeds to which
the packing is exposed There are ba-
sically three types of mixersagitators
top- bottom- and side-entry Top-entry
models are subject to the same con-
cerns about shaft run-out ldquowhiprdquo and
lateral forces on the paddles that are
encountered in some vertical pumps
Although some fluid may splash onto
the packing these mixers basically run
dry so the packing must have the abil-
ity to dissipate the resulting frictional
heat
In bottom-entry mixers the packing
is always exposed to fluid and may also
be exposed to solids requiring abra-
sion-resistance If the seal fails the en-
tire contents of the tank will eventually
drain out onto the bearings the floor
and other components under the stuff-
ing box
The packing in side-entry mixers may
be fully or intermittently exposed to flu-
id as well as side loading and vibration
Aside from media temperature
speed and other application variables
the configurations and operating prin-
ciples of rotary-type pumps exert differ-
ent forces on the seals used to keep
them from leaking These forces can
spell the difference between accept-
able seal performance and failure
Understanding these differences has
important implications that should be
taken into account to assure proper
sealing selection for long-term trou-
ble-free performance FC
wwwgarlockcom
Chris Boss is
a senior applica-
tions engineer for
Garlock Sealing
Technologies in
Palmyra NY He
has held various
positions in produc-
tion engineering
product development and applica-
tions engineering for the companyrsquos
compression packing division He
is a BSME graduate of the State
University of New York at Buffalo Mr
Boss can be reached at 800 448-
6688 or chrisbossgarlockcom
Chris Boss
Cavitation | Centrifugal Pump | Pump Packing | Sealing System
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Figure 9
Figure 10
Aside from media temperature speed and
other application variables the configurations
and operating principles of rotary-type
pumps exert different forces on the seals used
to keep them from leaking These forces can
spell the difference between acceptable seal
performance and failure
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3445
NS IDERNDUSTRIAL AUTOMATION + PROCESS CONTROL
WANT
INFORMATION
ON THE
automationindustry
SUBSCRIBE NOW at wwwiainsidercouk
Published by Spitzer and Boyes LLC Write in 15 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
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Frost says the push from developing
economies is important as the market
is technologically mature and seeing
restricted growth in developed econo-
mies This is particularly true in Europe
and North America where recent finan-
cial insta-
bility has
reduced capital expenditure across end-
user industries
Bill Moore senior vice president of
sales development and channel man-
agement for global bearings manufac-
turer SKF says ldquosmartrdquo products and
the expansion of robust reliability pro-
grams are helping to drive new invest-
ment particularly in developed coun-
tries where the cost to compete is
high Frost says the magnitude of
the existing global installed base will
strengthen the need for replacement
and upgrades adding to market de-
mand as well
Frost says despite the potential
in developing economies the focus
on price as a product differentiator
may lead to intense price pressures
among manufacturers and bring down
the value of the overall market in the
short term The growing trend among
consumers to choose low-cost Chinese
imports will complicate this challenge
As price and quality become stan-
dardized across the globe customers
will base more of their purchasing deci-
sions on value-added services accord-
ing to Frost This will push manufactur-
ers to create more maintenance-free
solutions such as lubrication-free
bearings that offer end-users savings
on service and replacement costs and
reduce downtimeldquoOffering a complete line of prod-
ucts with comprehensive services will
be another feather in the cap of ven-
dors looking to widen their consumer
baserdquo notes Frost Industrial Automa-
tion and Process Control Research
Analyst Guru Mahesh
Moore says the trend of outsourcing
manufacturing to regions where labor
and production costs are favorable is
becoming less of a factor
ldquoThe days when cheap labor made
a significant difference in where a prod-
uct is manufactured mdash particularly high
value-added products or high weight
and bulk products mdash are coming to
an end as the cost of transportation
storage and inventory balance out the
benefits of production costs where la-
bor is a smaller percentage of the cost
of manufacturingrdquo Moore says ldquoLocal
manufacturing development will indeed
come to developing countries as their
ability to create markets that generate
economies of scale that support local
production is a clear trend and one that
all manufacturers will pay attention tordquo
Moore says that development of
maintenance-free or predictive tech-
nologies and products will be a sig-
nificant advantage to everyone in the
Bearing amp Coupling Manufacturers Focus
onDEVELOPING Economies
amp EFFICIENCY InnovationBy Amy W Richardson
2 January 2015
Flow Control Magazine
|
gy
Anew study from Frost amp Sullivan (wwwfrostcom) fore-
casts steady growth for the overall bearings and couplings
market based on rapid industrial development in high-growth
regions Specifically Frost predicts development in Mexico
Indonesia Nigeria Turkey Brazil Russia India and Chinawill help boost the bearings amp couplings market from $2206
billion in 2013 to an estimated $2676 billion in 2018
The development of maintenance-freeor predictive technologies will helpboost growth in the bearings market For example SKF is developing products that will automatically notifyusers when a bearing or mechanicalrotating component is approachingthe end of its useful life Pictured hereis an SKF Microlog analyzer a por- table condition monitoring tool
COURTESY SKF
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
improved productivity through simplified solutions The powerful technology and tools ensure repeatable
reliable accurate measurements Easier access to process data allows for better troubleshooting process
optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
For daily product notes visit the lsquoFeatured Productsrsquo section flowcontrolnetworkcom
ON THE WEB
1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3845
FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
and benefits as well as grids of
instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
services provided for the
mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
Brought to you by Beamex
Your Source For Fluid Handling Videos
Go towwwflowcontrolnetworkcomfreeinfo
Select appropriate issue ofFlow Control Magazine
Select advertisements thatinterest you
Enter your email amp clickldquoSubmit Requestrdquo
1
2
3
4
PRODUCT
INFORMATION
ONLINE
Follow these 4 steps to receive freeproduct information from suppliers
FREE
FEATURED VIDEO How to Calibrate aPressure Measurement Loop
For more information about FlowTube
sponsor packs email FlowControlGrandViewMediacom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4245
THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
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Title _________________________________________________________________
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______________________________________________________________________
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One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
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On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
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7232019 Flow Control January 2015
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The bottom line is the volume of gas under one set of
pressure and temperature conditions is not the same as it
would be for the gas under different conditions Why is thisimportant Without compensation for compressibility read-
ings taken by gas flowmeters can result in measurementsmdash
and costs to the buyermdashsignificantly lower or higher than they
should be
The flow of gas in a system can be accounted for and
reported in a number of ways such as by volume by mass
flowrate and by energy Inline turbine meters can offer both
reliability and accuracy in measuring gas flow when matched
with a monitor capable of calculating and displaying results
that have been adjusted for the nature of the gas and impor-
tantly the pressure and temperature
Measuring Flow with an Inline TurbineFlowmeter
With an inline turbine meter gas flows into the meter through
a length of piping that helps to pre-condition the flow by
reducing undesirable swirls and asymmetry Where consid-
ered necessary a flow straightener may even be installed in
line to create a uniform flow profile to the extent possible
As can be seen in Figure 1 a rotor support within the tur-
bine housing further conditions the flow and directs it through
the blades of the rotor High-precision ball bearings allow the
rotor to freely rotate on the shaft
The rotorrsquos rotational speed is directly proportional to the velocity of the fluid passing through the meter The rotor itself
incorporates magnets (or magnetic blades depending on thedesign) while the housing is non-magnetic
A proximity sensor (also known as a pickup coil) is located
in line with the rotor and detects the electrical pulses gener-
ated by the ferrous rotor spinning through the magnetic field
Each pulse represents a discrete volume of gas The out-
put frequency provides the indication of the gas flow rate and
the accumulated pulses over a specified time represent the
total volume of fluid for that measurement period
Need for Calibration The flowrate of the gas through the meter cannot be deter-
mined accurately unless the meter is calibrated The fac-tory calibration determines the meterrsquos constant known
as a K-factor which is then inputted into the gas monitor
PPLICATION NOTES | Flow Measurement
20 | January 2015
Flow Control Magazine
COMPENSATING for
Compressibility inMeasuring Gas Flow Why K-factor adjustment is essential foraccurate inline turbine flow measurement
Unlike crude oil and other liquid fossilfuels natural gas poses a challenge
in monitoring the quantity of gas flowing
through pipelines While liquids do not com-
press gases do and the mass flowrate of
gas being transmitted through gathering
lines depends on both the pressure and
temperature
By Kevin Clark
Figure 1 Internal components of a liquid turbine flowmeter
C O U R T E S Y
T U R B I N E S
I N C
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2445
Wondering Whether the
Pump Guy Seminar
Is for YouCheck out the ldquoPump Guy Insightsrdquo
video series flwctrlcompginsights
PUMP GUY INSIGHT 1NPSHa vs NPSHrmdashWhy all pumps need gauges
PUMP GUY INSIGHT 3How to Operate Your Pump at Best Efficiency
PUMP GUY INSIGHT 5Head vs Flow
PUMP GUY INSIGHT 2 Your Pumps Are Constantly Moving On Their Curves
PUMP GUY INSIGHT 4 The Role of the Pump Reliability Chain
PUMP GUY INSIGHT 6How to Read a Pump Curve
PARTNER SPONSORSFor more information and to register
for upcoming Pump Guy Seminars
visit FlowControlNetworkcomPumpGuy
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2545
PPLICATION NOTES | Flow Measurement
22 | January 2015
Flow Control Magazine
Gas flowmeters measure the actual volume of gas passing
through the meter per minute irrespective of pressure and
temperature1
The volumetric flowrate of a gas is often corrected to
ldquostandardizedrdquo conditions of pressure and temperature While
ldquostandardrdquo conditions can vary depending on the definition
in the US this typically means a pressure of 1473 PSIA(pounds per square inch absolute) and a temperature of 60 F
The flowrate measurement is reported in standard cubic feet
per minute (SCFM)
Compensating for changes in pressure and temperature is
critical Consider a meter system setup for flowing conditions
of 60 PSIG (pounds per square inch gauge) and 60 F and the
line pressure decreases to 50 PSIG while the temperature
remains constant The difference in SCFM between the two
is more than 15 percent which would cost the buyer more
for the gas than it should As Table 1 demonstrates even a
small variation in pressure will result in a surprisingly high er-
ror percentage
Automation of the K-Factor The K-factor is established by an initial factory calibration In
the case of a non-compensated flow monitor any variations
in pressure and temperature will result in manual adjust-
ments needed to the K-factor In order to maintain accurate
flow measurement users must monitor pressure and temper-
ature and make corresponding adjustments to the K-factor To eliminate these manual adjustments some suppliers offer
a flow monitor that automatically adjusts for any changes in
pressure and temperature
These monitors provide accurate flow measurement regard-
less of changing environmental conditions in some cases sup-
porting applications with pressures as high as 15000 PSIG and
temperatures between -350 F to 350 F with a standard accura-
cy of +-1 percent over a flow range of 05 ACFM to 650 ACFM
Final NotesDuring the operation of a flowmeter system the ability to obtain
a readout mdash and to adjust for line pressure and temperaturechanges mdash is sometimes compromised by a lack of electric
power This issue is especially true along gas pipelines in remote
areas To overcome this limitation some manufacturers have
designed low-powered flow monitors which can operate for up
to on year on a single lithium D-cell battery
It is important for users to recognize the effects of the
compressibility of gas As such the quantity of a gas flow-
ing through a gas flowmeter depends on the pressure and
temperature In order to ensure accuracy any flowmetering
system must employ a means to correct for these effects
Otherwise the readout is certain to be in error and could be
unnecessarily costing money This is particularly crucial onwellhead production and in billing scenarios FC
wwwturbinesincorporatedcom
Notations1 The measurement factor in the US is known as the
ACFM actual cubic feet per minute (Metric units are typically
ACMH actual cubic meters per hour)
Table 1 Error induced by line pressure changes
Constant Temperature with Varying Pressure
Pressure Temperature PulsesSCF Error
50 60 2556027821 1546
51 60 2517123288 1370
52 60 2479385307 1199
53 60 2442762186 1034
54 60 240720524 873
55 60 237266858 717
56 60 2339108911 566
57 60 2306485356 418
58 60 2274759285 275
59 60 2243894166 136
60 60 2213855422 000
61 60 2184610304 132
62 60 2156127771 261
63 60 2128378378 386
64 60 210133418 508
65 60 2074968632 627
66 60 2049256506 743
67 60 2024173807 857
68 60 1999697703 967
69 60 1975806452 1075
70 60 1952479339 1181 Flow Measurement | K-Factor | Measurement
Accuracy | Turbine Flowmeter
Find related content flowcontrolnetworkcomhellipSearch on
FLOWSTREAM
Kevin Clark is senior develop-
ment engineer for Turbines Research
amp Development LLC Turbine RampD is a
subsidiary and the research and techni-
cal support arm of Turbines Inc which
serves a range of industries and applica-
tions from oil amp gas to cryogenic liquids
to custody transferKevin Clark
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2645
Pumps Bearings amp Seals TECHNOLOGY REPORT
FEATURES
SYSTEMS DESIGN
The ComplicatedCase of
Compressors
withSide-Streams
24 28 32BEST PRACTICES
How PumpingSystems
AffectSealing
Performance
TECH OUTLOOK
BearingSuppliers
Drive Gains InDeveloping
Markets
wwwflowcontrolnetworkcom January 2015 | 23
S P E C I AL S E C T I O N
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2745
The design and operation of compressors with side-
streams has always been difficult because flow entering the
compressor needs to be mixed with the core flow already
in the compressor (compressed in section-1) in a manner
that does not degrade the aerodynamic performance of sur-
rounding sections Minimizing losses and ensuring proper
mixing of the side-stream flow and core-flow are required to
ensure effective performance of a compressor of this sort
Key considerations for an application involving compres-
sors with side-stream flow include
The plant process typically dictates the side-stream
flange pressure
The impellers upstream of the side-stream should
achieve the necessary pressure for the core-flow
The side-stream flow is typically at a temperature dif-
ferent from compressor core-flow temperature
Process plants need some degree of operational flex-
ibility ie the ability to support variations in core-flow condi-
tions and side-stream conditions
Modern process plants are usually specifying more than
one operating conditions (sometimes two or more manda-
tory conditions) which can present challenges to compres-
sors with side-streams Adding to these issues modern
compressors should operate with much higher impeller tip
The COMPLICATED CASE ofCompressors with Side-StreamsConsidering key system design requirements
to ensure operational efficiency By Amin Almasi
4 January 2015
Flow Control Magazine
|
y
g
Some compressors in certain applications
have one or more incoming side-streams
(or side-loads) that introduce side-stream
flow to mix with the core flow In other words
a radial side-stream inlet is utilized in multi-
impeller centrifugal compressors to introduce
additional gas into the mid-stage of a com-
pressor This design enables optimization in
some process plants However the flow dis-
tribution after the junction of the side-stream
and the main return channel of the upstream
section can significantly affect the perfor-mance of the next section of compressor
In most cases the pressure levels at these
side-streams should be accurately predicted
to meet the theoretical performance
Compressor station at a natural gas processing plant
R U D M E R Z W E R V E R I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2845
speeds and inlet Mach numbers compared to previous
generations of compressor technology
Likewise side-streams are now com-
monly used with medium-sized and
large-sized compressors (eg 1ndash60
MW) The costs associated with cor-
rections on side-stream compres-
sor applicationsmdashany repair
inefficient operation and power
lossesmdashwould be very high Fur-
ther compressors with side-streams
are usually sensitive and difficult
machines to operate In particular
performance curves (performance
pressures efficiency etc) are sen-
sitive to suction inlet conditionsside-stream inlet conditions vol-
ume flow ratio (side-stream vol-
ume to core-flow volume) and side-stream losses
Compressors with side-stream often perform far below
expectations The main reason is that side-stream compres-
sors are different than conventional compressors (without
a side-stream) in design and operation For a compressor
with side-streams tighter tolerances in operating conditions
must be identified and applied Uncontrolled variations of
suction pressure or side-stream pressure are major prob-
lems Another major issue is the variations of the flow ratio
(side-stream flow to core-flow)
Compressor Side-Stream amp Mixing SectionIn many centrifugal compressors the portion of the side-
stream system from the flange connection to the mixing
section is similar to a compressor inlet A great challenge
is ensuring the mixing section provides circumferentially
uniform merged-flow with minimum losses This can be
achieved via effective design of the inlet configuration and
mixing section of the side-stream compressor such that
the impeller can be maintained over the whole operating
range of the compressor In many cases while there are
mixing sections provided for the machine the flows do not
completely mix before entering the impeller of the section-2
(the impeller after the mixing section) Non-uniformity at
inlet flow to the impeller is a key concern for compressor
performance
Another consideration is a compact design of the side-
stream mixing section Specifically a mixing section with
less axial length is always preferred This axial length can af-
fect the compressor rotor dynam-
ics the rotor length and over-
all compressor performance
(design cost operation and
reliability)
The side-stream exit pressure
(side-stream pressure at inlet
of the mixing section) is mainly
a function of the side-stream
flow velocity and the pres-
sure in the previous section of
the compressor Conversely the side-
stream flange pressure can depend on
side-stream flow velocity and section-1
exit conditions Therefore the side-stream
inlet flange volume flow is a function of theflange pressure compressibility (at that
pressure and temperature) and mass flow
Some engineers assume that the side-stream flange pres-
sure is equal to the inlet pressure of the first impeller of the
section-2 This is not true The mixed total pressure can be
estimated on a mass-averaged basis using side-stream total
pressure and return channel exit (section-1) total pressure
In some designs because of the lower static pressure at
the side-stream exit the total pressure at the return channel
exit is lower even though the velocity upstream is roughly
matched for both streams The pressure usually increased
at the returned channel but it can be reduced again at the
side-stream exit While simple in nature this can have an
impact on the prediction of pressure at the side-stream exit
and overall mixing section performance Based on basic flow
principles it was usually assumed that the static pressure
was equal between both flow streams at the mixing location
While this assumption might be used in rough calculations
the accurate simulations have shown this assumption is not
true In fact there are some points (for instance the shroud
wall at the exit of the return channel and the hub wall at
the exit of the side-stream) where this assumption is true
However this is not valid for all locations There are pressure
changes that occur from a side-stream flange to the inlet
of the next section (section-2) which depend on different
factors The first factor is the frictional losses due to side-
stream geometry from side-stream flange to plenum mix-
ing section etc The other factors are pressure changes due
to local curvature and geometry details of mixing section
Another consideration is the operation of a compressor
with side-stream at part-load The performance of the side-
wwwflowcontrolnetworkcom January 2015 25
Figure 1 An example of a centrifugalcompressor with side-stream
COURTESY SIEMENS
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 29456 January 2015
Flow Control Magazine
|
y
g
stream path the mixing section and
the downstream impellers when ma-
chine is operated at part-load or even
off-design operating flows will result
in additional compressor performance
problems In such a case both veloc-
ity profiles and pressure variations in
various parts (side-stream path mixing
section etc) will be different resulting
in complicated flow patterns and com-
plex aerodynamics behaviors
Side-Stream CompressorSectional Performance
Typically vendor-supplied compressor
performance curves reflect flange-to-flange performance because that is
what the plant engineers need to
evaluate the proper operation of their
system (for example from suction to
side-stream and from side-stream to
discharge) In many cases compres-
sor vendors also provide the over-
all compressor performance curves
and performance curves for section-1
(from suction to side-stream) and sec-
tion-2 (from side-stream to discharge)
Flange-to-flange data if not interpret-
ed properly can lead to false conclu-
sions about the relative performance
of individual sections of a compression
system For example if side-stream
losses from the flange to mixing sec-
tion are attributed to the downstream
section (section-2) it will cause the
downstream section (section-2) to
appear low in performance while the
upstream section (section-1) will show
high performance levels
An important behavior to con-
sider is when the actual side-stream
pressure is different than the rated
side-stream pressure When the side-
stream pressure is slightly higher than
the outlet pressure of the section-1
it (section-1) shows a relatively higher
performance compared to the real sec-
tion-1 performance In some cases
the performance of section-1 could be
considerably higher than section-2 In
other words when performance is de-
termined flange to flange the higher
flange pressure is seen as extra ldquopseu-
dordquo work done by the section (since this
is an inconsistent thermodynamic vol-
ume) resulting in a relatively high sec-
tional efficiency (section-1 shows a rel-
atively high efficiency) This is the case
for many compressors with side-stream
because the whole system is designed
(or specifically the side-stream location
is selected) in a way aimed at main-
taining the real side-stream pressure(side-stream inlet) above the section-1
outlet pressure because if the real side-
stream pressure becomes lower than
the section-1 outlet pressure the flow
may (theoretically) reverse
This is particularly important when
the side-stream mass flow is much
lower than the mass flow of core-flow
The above-mentioned reasons explain
why in many simulations calcula-
tions and performance reports related
to compressors with side-stream the
section-1 shows a relatively good ef-
ficiency and section-2 appears low in
efficiency
When the side-stream pressure is
slightly lower than the outlet pressure
of the section-1 the section-1 might
show a relatively lower performance
compared to section-2 This could oc-
cur in some recycle services where the
side-stream is actually a recycle flow
with a mass flow around two to five
times the core-flow The side-stream
(recycle) flow is returned from down-
stream of the compressor to be slightly
compressed and recycled to the down-
stream Such a recycled side-stream
compressor can present unique chal-
lenges for design and operation This
kind of machine usually needs very
special operating procedures and very
fine adjustments regarding operating
pressures and flows
Side-Stream Compressor
Performance amp Operation An important consideration is the sen-
sitivity of compressor overall perfor-
mance curve and sectional perfor-
mance curves to the flow ratio (ratio
of side-stream flow to core-flow) and
to the inlet conditions Variations in
the flow and pressure of the main
suction and side-stream inlet should
be controlled within tight tolerances
For compressors with side-stream the ASME PTC-10 code stipulates limits on
flow ratio (side-stream volume to core-
flow volume) The acceptable variation
in volume flow ratio in a compressor
with a side-stream is +-5 percent as
per ASME PTC code The requested
side-stream pressure tolerance is not
usually specified in compressor codes
but it should be around +- 2 percent
(or sometimes +- 25 percent)
Variance in flow ratio impacts the
velocity levels where the two streams
merge Significant variation in the ve-
locity profile upstream of the impeller
changes the incidence on the blade
leading edge of the following impel-
ler This change in incidence leads to a
change in sectional performance over-
all compressor performance and train
efficiency
If the flow ratio is varied between 95
percent and 105 percent (tolerances
specified in the ASME PTC-10 code)
the flange pressure changes accord-
ingly resulting in a change in the sec-
tional performance and overall perfor-
mance The sectional efficiency varies
sometimes more than +- 4 percent
This variance reduces as the flow is de-
creased toward surge However as the
flow is increased toward overload the
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3045wwwflowcontrolnetworkcom January 2015 27
variance increases up to higher values
(even in some cases three to five times
compared to variations near the surge
zone) For example in a case study
for a compressor with side-streams a
+- 5 percent variation in flow ratio and
associated changes (pressures losses
etc) the sectional efficiency reduced by
approximately 34 percent at the rated
flow at allowable operating points at
the end of curve (near the overload
ie choke) efficiency reduced by ap-
proximately 55 percent These results
show that the variation in sectional
performance and overall performance
due to flow ratio is highest at operat-ing points near the overload and low-
est at operating points near the surge
For compressors which work most of
the time at high flow (flow higher than
rated flow and discharge pressure low-
er than rated pressure) the effects of
flow ratio deviations (and subsequently
efficiency reduction) would be higher
than compressors working on the left-
hand side of curve (say with sufficient
margins near the surge)
In the compressor codes (such as
API 617) the compressor power varia-
tions should be maintained below 4
percent However in some applica-
tions clients require tighter tolerances
on the consumed power sometimes
below 2 percent (or even below 15
percent) Some studies suggest while
+- 5 percent of volume flow ratio is
suitable for performance test as per
ASME PTC-10 code some plants re-
quire tighter control on the consumed
power and compressor performance
(lower limits on the efficiency) the tol-
erances on the volume flow ratio could
be tighter than ASME PTC code In this
regard +- 4 percent tolerance can be
suggested on the volume flow ratio (ra-
tio of side-stream flow to core-flow) of
compressors with side-streams
Based on operational experiences
acceptable variations in volume flow
ratio and inlet pressures (suction inlet
and side-stream inlet) of a compressor
with side-streams are +- 4 percent
and +- 2 percent respectively
Another important consideration is
the required adjustments for the flow
ratio (side-stream flow to core-flow)
Compressors with side-stream usually
require fixed side-stream flange pres-
sures For a compressor with some variations in operation conditions (even
small changes) it is not usually pos-
sible to achieve optimum operation by
keeping the flow ratio (side-stream to
core-flow) constant The flow ratio has
to be adjusted according to the inlet
flow at which the machine is operating
in order to get the required correspond-
ing side-stream flange pressure
Thermal changes have also been
known to cause some instability in
centrifugal compressors An example is
the thermal-induced change of resid-
ual unbalance For compressors with
side-streams which feature tempera-
ture differences between core-flow and
side-stream flow the thermal behav-
ior of the compressor is usually more
complex and requires more attention
Heavy Gas ChallengeHeavy gases (such as heavy hydrocar-
bon gases eg propane propylene
MTBE (Methyl Tertiary Butyl Ether))
have very low gas sonic velocities that
produce high Mach numbers in the
aerodynamic flow paths For these
services because of high Mach num-
ber high flow coefficient stages have
very narrow flow maps characterized
by limited surge and choke margins
Compressors with side-streams in
these services present great challeng-
es This is to say the side-streams and
associated mixing further complicate
design operation and performance
prediction because the pressure tem-
perature and flow conditions at each
one of these side-streams as well
as at the exit of the machine require
stringent tolerances to optimize the
overall efficiency and performance
As such it is important to accuratelymodel design operate and moni-
tor performance characteristics of any
impellers diffusers return channels
and generally all flow-path components
in a compressor with side-stream FC
Amin Almasi
is a senior rotating
machine consultant
in Australia He is
a chartered profes- sional engineer of
Engineers Australia
(MIEAust CPEng ndash
Mechanical) and
IMechE (CEng MIMechE) holds
bachelorrsquos and masterrsquos degrees
in Mechanical Engineering and is
a registered professional engineer
in Queensland He specializes in
rotating machines including cen-
trifugal screw and reciprocating
compressors gas turbines steamturbines engines pumps subsea
offshore rotating machines LNG
units condition monitoring and reli-
ability Mr Almasi is an active mem-
ber of Engineers Australia IMechE
ASME and SPE He can be reached
at aminalmasiymailcom
Amin Almasi
Compressor | Gas Flow | Performance Curve | Side-Stream Flow
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3145
The pressure in the stuffing box
containing the packing can be estimat-
ed by the following equation
SBP = [Discharge ndash Suction] 3 + Suction
Pressure at the bottom of the stuff-
ing box will be higher than the suction
pressure but considerably lower than
the discharge pressure It should be
noted this calculation will yield a con-
servative estimate of stuffing box pres-
sure that can be further reduced by
pump design
A hole in the stuffing box serves as
a port for injecting clean fluid that cir-
culates around a lantern ring aligned
under the flush port The fluid flushes
solids back into the process to protect
the packing from abrasive wear If the
clean fluid is injected at a pressure ex-
ceeding that at the bottom of the stuff-
ing box some of it will leak back into
the process and some will leak out to
the atmosphere Recommended flush
injection pressure is 15ndash30 PSI (1ndash2
Bar) greater than the pressure at the
bottom of the stuffing box
Fluid injection is also used to lubri-
cate and cool dry-running packing that
is subject to frictional heat and to pre-
vent air from entering the pump which
reduces flow and operating efficiency
Centrifugal pumps utilize three
types of impellersmdashopen semi-open
and closed (Figures 2 3 amp 4) Open
designs prevent fluids with large solids
from clogging the impellers but at theexpense of pump efficiency Backing
plates on semi-open designs serve to
trap the fluid for more efficient opera-
tion Closed impellers are for use with
clean fluids since solids could ac-
cumulate in the eye which would re-
quire tearing down the pump to remove
them
Single-Stage CentrifugalPumpsSingle-stage centrifugal pumps typi-
cally have good bearing support of the
shaft with few run-out or ldquowhiprdquo prob-
lems However in some cases they
are subject to cavitation This occurs
in the eye of the impeller where the
fluid is under vacuum If the pressure
is low enough it will cause the material
to vaporize forming air or water vapor
bubbles As the fluid passes through
How Pumping Systems Design Affects Sealing Performance
By Chris Boss
8 January 2015
Flow Control Magazine
|
Understanding how different types of pump designs impact
sealing is critical to optimizing efficiency safety and lon-
gevity of the sealing system Used for a wide variety of media
including clear fluids solutions and slurries single-stage
centrifugal pumps are one of the most common
types (Figure 1) Fluid drawn into these pumps
enters the eye of an impeller that spins itto the outside of its container
or volute building pressure as
it moves toward discharge
Some of this fluid will work
its way behind the impeller
where it must be sealed with
compression packing or a
mechanical seal
Figure 1
Figure 2 Figure 3 Figure 4
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3245
the pump under increasing pressure
these bubbles implode sending shock
and vibration through the impeller
adversely affecting the seal This phe-
nomenon can be mitigated by running
the pump at slower speed and higher
pressure at the suction end to prevent
air from entering the fluid
Double-Ended Split-CasePumpsOperating on the same centrifugal prin-
ciple but slightly different geometry are
double-ended split-case pumps (Figure
5) Fluid enters both ends of the pump
and is directed into the eye of an impel-ler which spins it out of the volute to
discharge Packing is installed on both
the shaft and bearing ends so the stuff-
ing box is exposed only to suction pres-
sure which is usually quite low
Axial Flow Pumps Axial flow pumps operate like hydro
turbines in reverse whereby a propeller
(or axial impeller) pushes the fluid to
discharge (Figure 6)
Since the stuffing box is located
downstream of the propeller at the dis-
charge end of the pump the packing is
exposed to the full discharge pressure
Vertical PumpsVertical turbine pumps are typically
flange-mounted on a floor extending
downward into a water-filled sump
hole (Figure 7) Available as single- or
multi-stage pumps they feature an
impeller or series of impellers rotated
simultaneously by a single shaft The
impellers increase the pressure of the
upward flow subjecting the stuffing box
to full discharge pressure
Vertical pumps can be quite long so
inadequate bearing support can cause
the shaft to run out This can induce
undesirable lateral motion on the pack-
ing Worse the packing may be forced
to serve both as a bearing and a seal To
withstand these conditions the packing
should be resilient elastic and resistant
to deformation These properties rule
out packing such as graphite foil in favor
of fiber-based materials
Multi-Stage PumpsMulti-stage pumps are used for high-
pressure applications such as feeding
the boilers in steam-powered generating
plants Stuffing box pressure can vary
with pump design and number of stag-
es Designed for clean fluids and high
operating speeds these pumps typically
have high- and low-pressure ends with ahydraulic pressure equalization line run-
ning between the stuffing boxes
Like vertical pumps multi-stage
pumps feature a series of impellers to
build fluid discharge pressure In the
case of the six-stage pump pictured in
Figure 8 fluid enters at the drive end
where a stuffing box is exposed to suc-
tion pressure Channeled from one
impeller to the next through the pump
casting the fluid can reach extremely
high pressures at discharge
A second stuffing box located at the
bearing end is exposed to an intermedi-
ate pressure from the third impeller This
pressure is greater than the suction pres-
sure but much less than the discharge
pressure which can reach 2000 PSI
Fortunately the stuffing boxes in
these pumps are not exposed to dis-
charge pressures and typically see be-
low 500 PSI which is within the range
of some packing materials
wwwflowcontrolnetworkcom January 2015 29
Figure 5
Figure 6
Figure 7
Figure 8
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 33450 January 2015
Flow Control Magazine
| Gear PumpsPositive-displacement or gear pumps
operate on a different principle than
centrifugal pumps In external gear
pumps the fluid flows around the out-
side of the gears the intermeshing
of which forces it through the pump
to discharge (Figure 9) This design
makes these pumps particularly suit-
able for use with highly viscous fluids
such as resins emulsions syrups and
adhesives As such they are used for
transfer or metering applications
It should be noted gear pumps will
continue to displace fluid as long as
their shafts are turning which can pose
a problem if a clog occurs at the dis-
charge The resulting buildup of pres-
sure can blow out seals and damage
the pump Therefore most gear pumps
have pressure relief valves to divert
fluid back to the suction side for re-
circulation through the pump Internal
gear pumps operate slightly differently
but also have pressure relief valves to
prevent damage from excessive pres-
sure (Figure 10) In both external and
internal gear pumps the maximum
stuffing box pressure is determined by
these valves
Other rotating equipment includes
mixersagitators which are similar to
pumps in terms of the speeds to which
the packing is exposed There are ba-
sically three types of mixersagitators
top- bottom- and side-entry Top-entry
models are subject to the same con-
cerns about shaft run-out ldquowhiprdquo and
lateral forces on the paddles that are
encountered in some vertical pumps
Although some fluid may splash onto
the packing these mixers basically run
dry so the packing must have the abil-
ity to dissipate the resulting frictional
heat
In bottom-entry mixers the packing
is always exposed to fluid and may also
be exposed to solids requiring abra-
sion-resistance If the seal fails the en-
tire contents of the tank will eventually
drain out onto the bearings the floor
and other components under the stuff-
ing box
The packing in side-entry mixers may
be fully or intermittently exposed to flu-
id as well as side loading and vibration
Aside from media temperature
speed and other application variables
the configurations and operating prin-
ciples of rotary-type pumps exert differ-
ent forces on the seals used to keep
them from leaking These forces can
spell the difference between accept-
able seal performance and failure
Understanding these differences has
important implications that should be
taken into account to assure proper
sealing selection for long-term trou-
ble-free performance FC
wwwgarlockcom
Chris Boss is
a senior applica-
tions engineer for
Garlock Sealing
Technologies in
Palmyra NY He
has held various
positions in produc-
tion engineering
product development and applica-
tions engineering for the companyrsquos
compression packing division He
is a BSME graduate of the State
University of New York at Buffalo Mr
Boss can be reached at 800 448-
6688 or chrisbossgarlockcom
Chris Boss
Cavitation | Centrifugal Pump | Pump Packing | Sealing System
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Figure 9
Figure 10
Aside from media temperature speed and
other application variables the configurations
and operating principles of rotary-type
pumps exert different forces on the seals used
to keep them from leaking These forces can
spell the difference between acceptable seal
performance and failure
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3445
NS IDERNDUSTRIAL AUTOMATION + PROCESS CONTROL
WANT
INFORMATION
ON THE
automationindustry
SUBSCRIBE NOW at wwwiainsidercouk
Published by Spitzer and Boyes LLC Write in 15 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3545
Frost says the push from developing
economies is important as the market
is technologically mature and seeing
restricted growth in developed econo-
mies This is particularly true in Europe
and North America where recent finan-
cial insta-
bility has
reduced capital expenditure across end-
user industries
Bill Moore senior vice president of
sales development and channel man-
agement for global bearings manufac-
turer SKF says ldquosmartrdquo products and
the expansion of robust reliability pro-
grams are helping to drive new invest-
ment particularly in developed coun-
tries where the cost to compete is
high Frost says the magnitude of
the existing global installed base will
strengthen the need for replacement
and upgrades adding to market de-
mand as well
Frost says despite the potential
in developing economies the focus
on price as a product differentiator
may lead to intense price pressures
among manufacturers and bring down
the value of the overall market in the
short term The growing trend among
consumers to choose low-cost Chinese
imports will complicate this challenge
As price and quality become stan-
dardized across the globe customers
will base more of their purchasing deci-
sions on value-added services accord-
ing to Frost This will push manufactur-
ers to create more maintenance-free
solutions such as lubrication-free
bearings that offer end-users savings
on service and replacement costs and
reduce downtimeldquoOffering a complete line of prod-
ucts with comprehensive services will
be another feather in the cap of ven-
dors looking to widen their consumer
baserdquo notes Frost Industrial Automa-
tion and Process Control Research
Analyst Guru Mahesh
Moore says the trend of outsourcing
manufacturing to regions where labor
and production costs are favorable is
becoming less of a factor
ldquoThe days when cheap labor made
a significant difference in where a prod-
uct is manufactured mdash particularly high
value-added products or high weight
and bulk products mdash are coming to
an end as the cost of transportation
storage and inventory balance out the
benefits of production costs where la-
bor is a smaller percentage of the cost
of manufacturingrdquo Moore says ldquoLocal
manufacturing development will indeed
come to developing countries as their
ability to create markets that generate
economies of scale that support local
production is a clear trend and one that
all manufacturers will pay attention tordquo
Moore says that development of
maintenance-free or predictive tech-
nologies and products will be a sig-
nificant advantage to everyone in the
Bearing amp Coupling Manufacturers Focus
onDEVELOPING Economies
amp EFFICIENCY InnovationBy Amy W Richardson
2 January 2015
Flow Control Magazine
|
gy
Anew study from Frost amp Sullivan (wwwfrostcom) fore-
casts steady growth for the overall bearings and couplings
market based on rapid industrial development in high-growth
regions Specifically Frost predicts development in Mexico
Indonesia Nigeria Turkey Brazil Russia India and Chinawill help boost the bearings amp couplings market from $2206
billion in 2013 to an estimated $2676 billion in 2018
The development of maintenance-freeor predictive technologies will helpboost growth in the bearings market For example SKF is developing products that will automatically notifyusers when a bearing or mechanicalrotating component is approachingthe end of its useful life Pictured hereis an SKF Microlog analyzer a por- table condition monitoring tool
COURTESY SKF
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
improved productivity through simplified solutions The powerful technology and tools ensure repeatable
reliable accurate measurements Easier access to process data allows for better troubleshooting process
optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
For daily product notes visit the lsquoFeatured Productsrsquo section flowcontrolnetworkcom
ON THE WEB
1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3845
FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
and benefits as well as grids of
instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
services provided for the
mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
Brought to you by Beamex
Your Source For Fluid Handling Videos
Go towwwflowcontrolnetworkcomfreeinfo
Select appropriate issue ofFlow Control Magazine
Select advertisements thatinterest you
Enter your email amp clickldquoSubmit Requestrdquo
1
2
3
4
PRODUCT
INFORMATION
ONLINE
Follow these 4 steps to receive freeproduct information from suppliers
FREE
FEATURED VIDEO How to Calibrate aPressure Measurement Loop
For more information about FlowTube
sponsor packs email FlowControlGrandViewMediacom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4245
THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
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Title _________________________________________________________________
Company _____________________________________________________________
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______________________________________________________________________
Phone ________________________________________________________________
E-Mail ________________________________________________________________
One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
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HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
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![Page 24: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/24.jpg)
7232019 Flow Control January 2015
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Wondering Whether the
Pump Guy Seminar
Is for YouCheck out the ldquoPump Guy Insightsrdquo
video series flwctrlcompginsights
PUMP GUY INSIGHT 1NPSHa vs NPSHrmdashWhy all pumps need gauges
PUMP GUY INSIGHT 3How to Operate Your Pump at Best Efficiency
PUMP GUY INSIGHT 5Head vs Flow
PUMP GUY INSIGHT 2 Your Pumps Are Constantly Moving On Their Curves
PUMP GUY INSIGHT 4 The Role of the Pump Reliability Chain
PUMP GUY INSIGHT 6How to Read a Pump Curve
PARTNER SPONSORSFor more information and to register
for upcoming Pump Guy Seminars
visit FlowControlNetworkcomPumpGuy
7232019 Flow Control January 2015
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PPLICATION NOTES | Flow Measurement
22 | January 2015
Flow Control Magazine
Gas flowmeters measure the actual volume of gas passing
through the meter per minute irrespective of pressure and
temperature1
The volumetric flowrate of a gas is often corrected to
ldquostandardizedrdquo conditions of pressure and temperature While
ldquostandardrdquo conditions can vary depending on the definition
in the US this typically means a pressure of 1473 PSIA(pounds per square inch absolute) and a temperature of 60 F
The flowrate measurement is reported in standard cubic feet
per minute (SCFM)
Compensating for changes in pressure and temperature is
critical Consider a meter system setup for flowing conditions
of 60 PSIG (pounds per square inch gauge) and 60 F and the
line pressure decreases to 50 PSIG while the temperature
remains constant The difference in SCFM between the two
is more than 15 percent which would cost the buyer more
for the gas than it should As Table 1 demonstrates even a
small variation in pressure will result in a surprisingly high er-
ror percentage
Automation of the K-Factor The K-factor is established by an initial factory calibration In
the case of a non-compensated flow monitor any variations
in pressure and temperature will result in manual adjust-
ments needed to the K-factor In order to maintain accurate
flow measurement users must monitor pressure and temper-
ature and make corresponding adjustments to the K-factor To eliminate these manual adjustments some suppliers offer
a flow monitor that automatically adjusts for any changes in
pressure and temperature
These monitors provide accurate flow measurement regard-
less of changing environmental conditions in some cases sup-
porting applications with pressures as high as 15000 PSIG and
temperatures between -350 F to 350 F with a standard accura-
cy of +-1 percent over a flow range of 05 ACFM to 650 ACFM
Final NotesDuring the operation of a flowmeter system the ability to obtain
a readout mdash and to adjust for line pressure and temperaturechanges mdash is sometimes compromised by a lack of electric
power This issue is especially true along gas pipelines in remote
areas To overcome this limitation some manufacturers have
designed low-powered flow monitors which can operate for up
to on year on a single lithium D-cell battery
It is important for users to recognize the effects of the
compressibility of gas As such the quantity of a gas flow-
ing through a gas flowmeter depends on the pressure and
temperature In order to ensure accuracy any flowmetering
system must employ a means to correct for these effects
Otherwise the readout is certain to be in error and could be
unnecessarily costing money This is particularly crucial onwellhead production and in billing scenarios FC
wwwturbinesincorporatedcom
Notations1 The measurement factor in the US is known as the
ACFM actual cubic feet per minute (Metric units are typically
ACMH actual cubic meters per hour)
Table 1 Error induced by line pressure changes
Constant Temperature with Varying Pressure
Pressure Temperature PulsesSCF Error
50 60 2556027821 1546
51 60 2517123288 1370
52 60 2479385307 1199
53 60 2442762186 1034
54 60 240720524 873
55 60 237266858 717
56 60 2339108911 566
57 60 2306485356 418
58 60 2274759285 275
59 60 2243894166 136
60 60 2213855422 000
61 60 2184610304 132
62 60 2156127771 261
63 60 2128378378 386
64 60 210133418 508
65 60 2074968632 627
66 60 2049256506 743
67 60 2024173807 857
68 60 1999697703 967
69 60 1975806452 1075
70 60 1952479339 1181 Flow Measurement | K-Factor | Measurement
Accuracy | Turbine Flowmeter
Find related content flowcontrolnetworkcomhellipSearch on
FLOWSTREAM
Kevin Clark is senior develop-
ment engineer for Turbines Research
amp Development LLC Turbine RampD is a
subsidiary and the research and techni-
cal support arm of Turbines Inc which
serves a range of industries and applica-
tions from oil amp gas to cryogenic liquids
to custody transferKevin Clark
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2645
Pumps Bearings amp Seals TECHNOLOGY REPORT
FEATURES
SYSTEMS DESIGN
The ComplicatedCase of
Compressors
withSide-Streams
24 28 32BEST PRACTICES
How PumpingSystems
AffectSealing
Performance
TECH OUTLOOK
BearingSuppliers
Drive Gains InDeveloping
Markets
wwwflowcontrolnetworkcom January 2015 | 23
S P E C I AL S E C T I O N
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2745
The design and operation of compressors with side-
streams has always been difficult because flow entering the
compressor needs to be mixed with the core flow already
in the compressor (compressed in section-1) in a manner
that does not degrade the aerodynamic performance of sur-
rounding sections Minimizing losses and ensuring proper
mixing of the side-stream flow and core-flow are required to
ensure effective performance of a compressor of this sort
Key considerations for an application involving compres-
sors with side-stream flow include
The plant process typically dictates the side-stream
flange pressure
The impellers upstream of the side-stream should
achieve the necessary pressure for the core-flow
The side-stream flow is typically at a temperature dif-
ferent from compressor core-flow temperature
Process plants need some degree of operational flex-
ibility ie the ability to support variations in core-flow condi-
tions and side-stream conditions
Modern process plants are usually specifying more than
one operating conditions (sometimes two or more manda-
tory conditions) which can present challenges to compres-
sors with side-streams Adding to these issues modern
compressors should operate with much higher impeller tip
The COMPLICATED CASE ofCompressors with Side-StreamsConsidering key system design requirements
to ensure operational efficiency By Amin Almasi
4 January 2015
Flow Control Magazine
|
y
g
Some compressors in certain applications
have one or more incoming side-streams
(or side-loads) that introduce side-stream
flow to mix with the core flow In other words
a radial side-stream inlet is utilized in multi-
impeller centrifugal compressors to introduce
additional gas into the mid-stage of a com-
pressor This design enables optimization in
some process plants However the flow dis-
tribution after the junction of the side-stream
and the main return channel of the upstream
section can significantly affect the perfor-mance of the next section of compressor
In most cases the pressure levels at these
side-streams should be accurately predicted
to meet the theoretical performance
Compressor station at a natural gas processing plant
R U D M E R Z W E R V E R I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2845
speeds and inlet Mach numbers compared to previous
generations of compressor technology
Likewise side-streams are now com-
monly used with medium-sized and
large-sized compressors (eg 1ndash60
MW) The costs associated with cor-
rections on side-stream compres-
sor applicationsmdashany repair
inefficient operation and power
lossesmdashwould be very high Fur-
ther compressors with side-streams
are usually sensitive and difficult
machines to operate In particular
performance curves (performance
pressures efficiency etc) are sen-
sitive to suction inlet conditionsside-stream inlet conditions vol-
ume flow ratio (side-stream vol-
ume to core-flow volume) and side-stream losses
Compressors with side-stream often perform far below
expectations The main reason is that side-stream compres-
sors are different than conventional compressors (without
a side-stream) in design and operation For a compressor
with side-streams tighter tolerances in operating conditions
must be identified and applied Uncontrolled variations of
suction pressure or side-stream pressure are major prob-
lems Another major issue is the variations of the flow ratio
(side-stream flow to core-flow)
Compressor Side-Stream amp Mixing SectionIn many centrifugal compressors the portion of the side-
stream system from the flange connection to the mixing
section is similar to a compressor inlet A great challenge
is ensuring the mixing section provides circumferentially
uniform merged-flow with minimum losses This can be
achieved via effective design of the inlet configuration and
mixing section of the side-stream compressor such that
the impeller can be maintained over the whole operating
range of the compressor In many cases while there are
mixing sections provided for the machine the flows do not
completely mix before entering the impeller of the section-2
(the impeller after the mixing section) Non-uniformity at
inlet flow to the impeller is a key concern for compressor
performance
Another consideration is a compact design of the side-
stream mixing section Specifically a mixing section with
less axial length is always preferred This axial length can af-
fect the compressor rotor dynam-
ics the rotor length and over-
all compressor performance
(design cost operation and
reliability)
The side-stream exit pressure
(side-stream pressure at inlet
of the mixing section) is mainly
a function of the side-stream
flow velocity and the pres-
sure in the previous section of
the compressor Conversely the side-
stream flange pressure can depend on
side-stream flow velocity and section-1
exit conditions Therefore the side-stream
inlet flange volume flow is a function of theflange pressure compressibility (at that
pressure and temperature) and mass flow
Some engineers assume that the side-stream flange pres-
sure is equal to the inlet pressure of the first impeller of the
section-2 This is not true The mixed total pressure can be
estimated on a mass-averaged basis using side-stream total
pressure and return channel exit (section-1) total pressure
In some designs because of the lower static pressure at
the side-stream exit the total pressure at the return channel
exit is lower even though the velocity upstream is roughly
matched for both streams The pressure usually increased
at the returned channel but it can be reduced again at the
side-stream exit While simple in nature this can have an
impact on the prediction of pressure at the side-stream exit
and overall mixing section performance Based on basic flow
principles it was usually assumed that the static pressure
was equal between both flow streams at the mixing location
While this assumption might be used in rough calculations
the accurate simulations have shown this assumption is not
true In fact there are some points (for instance the shroud
wall at the exit of the return channel and the hub wall at
the exit of the side-stream) where this assumption is true
However this is not valid for all locations There are pressure
changes that occur from a side-stream flange to the inlet
of the next section (section-2) which depend on different
factors The first factor is the frictional losses due to side-
stream geometry from side-stream flange to plenum mix-
ing section etc The other factors are pressure changes due
to local curvature and geometry details of mixing section
Another consideration is the operation of a compressor
with side-stream at part-load The performance of the side-
wwwflowcontrolnetworkcom January 2015 25
Figure 1 An example of a centrifugalcompressor with side-stream
COURTESY SIEMENS
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 29456 January 2015
Flow Control Magazine
|
y
g
stream path the mixing section and
the downstream impellers when ma-
chine is operated at part-load or even
off-design operating flows will result
in additional compressor performance
problems In such a case both veloc-
ity profiles and pressure variations in
various parts (side-stream path mixing
section etc) will be different resulting
in complicated flow patterns and com-
plex aerodynamics behaviors
Side-Stream CompressorSectional Performance
Typically vendor-supplied compressor
performance curves reflect flange-to-flange performance because that is
what the plant engineers need to
evaluate the proper operation of their
system (for example from suction to
side-stream and from side-stream to
discharge) In many cases compres-
sor vendors also provide the over-
all compressor performance curves
and performance curves for section-1
(from suction to side-stream) and sec-
tion-2 (from side-stream to discharge)
Flange-to-flange data if not interpret-
ed properly can lead to false conclu-
sions about the relative performance
of individual sections of a compression
system For example if side-stream
losses from the flange to mixing sec-
tion are attributed to the downstream
section (section-2) it will cause the
downstream section (section-2) to
appear low in performance while the
upstream section (section-1) will show
high performance levels
An important behavior to con-
sider is when the actual side-stream
pressure is different than the rated
side-stream pressure When the side-
stream pressure is slightly higher than
the outlet pressure of the section-1
it (section-1) shows a relatively higher
performance compared to the real sec-
tion-1 performance In some cases
the performance of section-1 could be
considerably higher than section-2 In
other words when performance is de-
termined flange to flange the higher
flange pressure is seen as extra ldquopseu-
dordquo work done by the section (since this
is an inconsistent thermodynamic vol-
ume) resulting in a relatively high sec-
tional efficiency (section-1 shows a rel-
atively high efficiency) This is the case
for many compressors with side-stream
because the whole system is designed
(or specifically the side-stream location
is selected) in a way aimed at main-
taining the real side-stream pressure(side-stream inlet) above the section-1
outlet pressure because if the real side-
stream pressure becomes lower than
the section-1 outlet pressure the flow
may (theoretically) reverse
This is particularly important when
the side-stream mass flow is much
lower than the mass flow of core-flow
The above-mentioned reasons explain
why in many simulations calcula-
tions and performance reports related
to compressors with side-stream the
section-1 shows a relatively good ef-
ficiency and section-2 appears low in
efficiency
When the side-stream pressure is
slightly lower than the outlet pressure
of the section-1 the section-1 might
show a relatively lower performance
compared to section-2 This could oc-
cur in some recycle services where the
side-stream is actually a recycle flow
with a mass flow around two to five
times the core-flow The side-stream
(recycle) flow is returned from down-
stream of the compressor to be slightly
compressed and recycled to the down-
stream Such a recycled side-stream
compressor can present unique chal-
lenges for design and operation This
kind of machine usually needs very
special operating procedures and very
fine adjustments regarding operating
pressures and flows
Side-Stream Compressor
Performance amp Operation An important consideration is the sen-
sitivity of compressor overall perfor-
mance curve and sectional perfor-
mance curves to the flow ratio (ratio
of side-stream flow to core-flow) and
to the inlet conditions Variations in
the flow and pressure of the main
suction and side-stream inlet should
be controlled within tight tolerances
For compressors with side-stream the ASME PTC-10 code stipulates limits on
flow ratio (side-stream volume to core-
flow volume) The acceptable variation
in volume flow ratio in a compressor
with a side-stream is +-5 percent as
per ASME PTC code The requested
side-stream pressure tolerance is not
usually specified in compressor codes
but it should be around +- 2 percent
(or sometimes +- 25 percent)
Variance in flow ratio impacts the
velocity levels where the two streams
merge Significant variation in the ve-
locity profile upstream of the impeller
changes the incidence on the blade
leading edge of the following impel-
ler This change in incidence leads to a
change in sectional performance over-
all compressor performance and train
efficiency
If the flow ratio is varied between 95
percent and 105 percent (tolerances
specified in the ASME PTC-10 code)
the flange pressure changes accord-
ingly resulting in a change in the sec-
tional performance and overall perfor-
mance The sectional efficiency varies
sometimes more than +- 4 percent
This variance reduces as the flow is de-
creased toward surge However as the
flow is increased toward overload the
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3045wwwflowcontrolnetworkcom January 2015 27
variance increases up to higher values
(even in some cases three to five times
compared to variations near the surge
zone) For example in a case study
for a compressor with side-streams a
+- 5 percent variation in flow ratio and
associated changes (pressures losses
etc) the sectional efficiency reduced by
approximately 34 percent at the rated
flow at allowable operating points at
the end of curve (near the overload
ie choke) efficiency reduced by ap-
proximately 55 percent These results
show that the variation in sectional
performance and overall performance
due to flow ratio is highest at operat-ing points near the overload and low-
est at operating points near the surge
For compressors which work most of
the time at high flow (flow higher than
rated flow and discharge pressure low-
er than rated pressure) the effects of
flow ratio deviations (and subsequently
efficiency reduction) would be higher
than compressors working on the left-
hand side of curve (say with sufficient
margins near the surge)
In the compressor codes (such as
API 617) the compressor power varia-
tions should be maintained below 4
percent However in some applica-
tions clients require tighter tolerances
on the consumed power sometimes
below 2 percent (or even below 15
percent) Some studies suggest while
+- 5 percent of volume flow ratio is
suitable for performance test as per
ASME PTC-10 code some plants re-
quire tighter control on the consumed
power and compressor performance
(lower limits on the efficiency) the tol-
erances on the volume flow ratio could
be tighter than ASME PTC code In this
regard +- 4 percent tolerance can be
suggested on the volume flow ratio (ra-
tio of side-stream flow to core-flow) of
compressors with side-streams
Based on operational experiences
acceptable variations in volume flow
ratio and inlet pressures (suction inlet
and side-stream inlet) of a compressor
with side-streams are +- 4 percent
and +- 2 percent respectively
Another important consideration is
the required adjustments for the flow
ratio (side-stream flow to core-flow)
Compressors with side-stream usually
require fixed side-stream flange pres-
sures For a compressor with some variations in operation conditions (even
small changes) it is not usually pos-
sible to achieve optimum operation by
keeping the flow ratio (side-stream to
core-flow) constant The flow ratio has
to be adjusted according to the inlet
flow at which the machine is operating
in order to get the required correspond-
ing side-stream flange pressure
Thermal changes have also been
known to cause some instability in
centrifugal compressors An example is
the thermal-induced change of resid-
ual unbalance For compressors with
side-streams which feature tempera-
ture differences between core-flow and
side-stream flow the thermal behav-
ior of the compressor is usually more
complex and requires more attention
Heavy Gas ChallengeHeavy gases (such as heavy hydrocar-
bon gases eg propane propylene
MTBE (Methyl Tertiary Butyl Ether))
have very low gas sonic velocities that
produce high Mach numbers in the
aerodynamic flow paths For these
services because of high Mach num-
ber high flow coefficient stages have
very narrow flow maps characterized
by limited surge and choke margins
Compressors with side-streams in
these services present great challeng-
es This is to say the side-streams and
associated mixing further complicate
design operation and performance
prediction because the pressure tem-
perature and flow conditions at each
one of these side-streams as well
as at the exit of the machine require
stringent tolerances to optimize the
overall efficiency and performance
As such it is important to accuratelymodel design operate and moni-
tor performance characteristics of any
impellers diffusers return channels
and generally all flow-path components
in a compressor with side-stream FC
Amin Almasi
is a senior rotating
machine consultant
in Australia He is
a chartered profes- sional engineer of
Engineers Australia
(MIEAust CPEng ndash
Mechanical) and
IMechE (CEng MIMechE) holds
bachelorrsquos and masterrsquos degrees
in Mechanical Engineering and is
a registered professional engineer
in Queensland He specializes in
rotating machines including cen-
trifugal screw and reciprocating
compressors gas turbines steamturbines engines pumps subsea
offshore rotating machines LNG
units condition monitoring and reli-
ability Mr Almasi is an active mem-
ber of Engineers Australia IMechE
ASME and SPE He can be reached
at aminalmasiymailcom
Amin Almasi
Compressor | Gas Flow | Performance Curve | Side-Stream Flow
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3145
The pressure in the stuffing box
containing the packing can be estimat-
ed by the following equation
SBP = [Discharge ndash Suction] 3 + Suction
Pressure at the bottom of the stuff-
ing box will be higher than the suction
pressure but considerably lower than
the discharge pressure It should be
noted this calculation will yield a con-
servative estimate of stuffing box pres-
sure that can be further reduced by
pump design
A hole in the stuffing box serves as
a port for injecting clean fluid that cir-
culates around a lantern ring aligned
under the flush port The fluid flushes
solids back into the process to protect
the packing from abrasive wear If the
clean fluid is injected at a pressure ex-
ceeding that at the bottom of the stuff-
ing box some of it will leak back into
the process and some will leak out to
the atmosphere Recommended flush
injection pressure is 15ndash30 PSI (1ndash2
Bar) greater than the pressure at the
bottom of the stuffing box
Fluid injection is also used to lubri-
cate and cool dry-running packing that
is subject to frictional heat and to pre-
vent air from entering the pump which
reduces flow and operating efficiency
Centrifugal pumps utilize three
types of impellersmdashopen semi-open
and closed (Figures 2 3 amp 4) Open
designs prevent fluids with large solids
from clogging the impellers but at theexpense of pump efficiency Backing
plates on semi-open designs serve to
trap the fluid for more efficient opera-
tion Closed impellers are for use with
clean fluids since solids could ac-
cumulate in the eye which would re-
quire tearing down the pump to remove
them
Single-Stage CentrifugalPumpsSingle-stage centrifugal pumps typi-
cally have good bearing support of the
shaft with few run-out or ldquowhiprdquo prob-
lems However in some cases they
are subject to cavitation This occurs
in the eye of the impeller where the
fluid is under vacuum If the pressure
is low enough it will cause the material
to vaporize forming air or water vapor
bubbles As the fluid passes through
How Pumping Systems Design Affects Sealing Performance
By Chris Boss
8 January 2015
Flow Control Magazine
|
Understanding how different types of pump designs impact
sealing is critical to optimizing efficiency safety and lon-
gevity of the sealing system Used for a wide variety of media
including clear fluids solutions and slurries single-stage
centrifugal pumps are one of the most common
types (Figure 1) Fluid drawn into these pumps
enters the eye of an impeller that spins itto the outside of its container
or volute building pressure as
it moves toward discharge
Some of this fluid will work
its way behind the impeller
where it must be sealed with
compression packing or a
mechanical seal
Figure 1
Figure 2 Figure 3 Figure 4
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3245
the pump under increasing pressure
these bubbles implode sending shock
and vibration through the impeller
adversely affecting the seal This phe-
nomenon can be mitigated by running
the pump at slower speed and higher
pressure at the suction end to prevent
air from entering the fluid
Double-Ended Split-CasePumpsOperating on the same centrifugal prin-
ciple but slightly different geometry are
double-ended split-case pumps (Figure
5) Fluid enters both ends of the pump
and is directed into the eye of an impel-ler which spins it out of the volute to
discharge Packing is installed on both
the shaft and bearing ends so the stuff-
ing box is exposed only to suction pres-
sure which is usually quite low
Axial Flow Pumps Axial flow pumps operate like hydro
turbines in reverse whereby a propeller
(or axial impeller) pushes the fluid to
discharge (Figure 6)
Since the stuffing box is located
downstream of the propeller at the dis-
charge end of the pump the packing is
exposed to the full discharge pressure
Vertical PumpsVertical turbine pumps are typically
flange-mounted on a floor extending
downward into a water-filled sump
hole (Figure 7) Available as single- or
multi-stage pumps they feature an
impeller or series of impellers rotated
simultaneously by a single shaft The
impellers increase the pressure of the
upward flow subjecting the stuffing box
to full discharge pressure
Vertical pumps can be quite long so
inadequate bearing support can cause
the shaft to run out This can induce
undesirable lateral motion on the pack-
ing Worse the packing may be forced
to serve both as a bearing and a seal To
withstand these conditions the packing
should be resilient elastic and resistant
to deformation These properties rule
out packing such as graphite foil in favor
of fiber-based materials
Multi-Stage PumpsMulti-stage pumps are used for high-
pressure applications such as feeding
the boilers in steam-powered generating
plants Stuffing box pressure can vary
with pump design and number of stag-
es Designed for clean fluids and high
operating speeds these pumps typically
have high- and low-pressure ends with ahydraulic pressure equalization line run-
ning between the stuffing boxes
Like vertical pumps multi-stage
pumps feature a series of impellers to
build fluid discharge pressure In the
case of the six-stage pump pictured in
Figure 8 fluid enters at the drive end
where a stuffing box is exposed to suc-
tion pressure Channeled from one
impeller to the next through the pump
casting the fluid can reach extremely
high pressures at discharge
A second stuffing box located at the
bearing end is exposed to an intermedi-
ate pressure from the third impeller This
pressure is greater than the suction pres-
sure but much less than the discharge
pressure which can reach 2000 PSI
Fortunately the stuffing boxes in
these pumps are not exposed to dis-
charge pressures and typically see be-
low 500 PSI which is within the range
of some packing materials
wwwflowcontrolnetworkcom January 2015 29
Figure 5
Figure 6
Figure 7
Figure 8
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 33450 January 2015
Flow Control Magazine
| Gear PumpsPositive-displacement or gear pumps
operate on a different principle than
centrifugal pumps In external gear
pumps the fluid flows around the out-
side of the gears the intermeshing
of which forces it through the pump
to discharge (Figure 9) This design
makes these pumps particularly suit-
able for use with highly viscous fluids
such as resins emulsions syrups and
adhesives As such they are used for
transfer or metering applications
It should be noted gear pumps will
continue to displace fluid as long as
their shafts are turning which can pose
a problem if a clog occurs at the dis-
charge The resulting buildup of pres-
sure can blow out seals and damage
the pump Therefore most gear pumps
have pressure relief valves to divert
fluid back to the suction side for re-
circulation through the pump Internal
gear pumps operate slightly differently
but also have pressure relief valves to
prevent damage from excessive pres-
sure (Figure 10) In both external and
internal gear pumps the maximum
stuffing box pressure is determined by
these valves
Other rotating equipment includes
mixersagitators which are similar to
pumps in terms of the speeds to which
the packing is exposed There are ba-
sically three types of mixersagitators
top- bottom- and side-entry Top-entry
models are subject to the same con-
cerns about shaft run-out ldquowhiprdquo and
lateral forces on the paddles that are
encountered in some vertical pumps
Although some fluid may splash onto
the packing these mixers basically run
dry so the packing must have the abil-
ity to dissipate the resulting frictional
heat
In bottom-entry mixers the packing
is always exposed to fluid and may also
be exposed to solids requiring abra-
sion-resistance If the seal fails the en-
tire contents of the tank will eventually
drain out onto the bearings the floor
and other components under the stuff-
ing box
The packing in side-entry mixers may
be fully or intermittently exposed to flu-
id as well as side loading and vibration
Aside from media temperature
speed and other application variables
the configurations and operating prin-
ciples of rotary-type pumps exert differ-
ent forces on the seals used to keep
them from leaking These forces can
spell the difference between accept-
able seal performance and failure
Understanding these differences has
important implications that should be
taken into account to assure proper
sealing selection for long-term trou-
ble-free performance FC
wwwgarlockcom
Chris Boss is
a senior applica-
tions engineer for
Garlock Sealing
Technologies in
Palmyra NY He
has held various
positions in produc-
tion engineering
product development and applica-
tions engineering for the companyrsquos
compression packing division He
is a BSME graduate of the State
University of New York at Buffalo Mr
Boss can be reached at 800 448-
6688 or chrisbossgarlockcom
Chris Boss
Cavitation | Centrifugal Pump | Pump Packing | Sealing System
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Figure 9
Figure 10
Aside from media temperature speed and
other application variables the configurations
and operating principles of rotary-type
pumps exert different forces on the seals used
to keep them from leaking These forces can
spell the difference between acceptable seal
performance and failure
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3445
NS IDERNDUSTRIAL AUTOMATION + PROCESS CONTROL
WANT
INFORMATION
ON THE
automationindustry
SUBSCRIBE NOW at wwwiainsidercouk
Published by Spitzer and Boyes LLC Write in 15 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
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Frost says the push from developing
economies is important as the market
is technologically mature and seeing
restricted growth in developed econo-
mies This is particularly true in Europe
and North America where recent finan-
cial insta-
bility has
reduced capital expenditure across end-
user industries
Bill Moore senior vice president of
sales development and channel man-
agement for global bearings manufac-
turer SKF says ldquosmartrdquo products and
the expansion of robust reliability pro-
grams are helping to drive new invest-
ment particularly in developed coun-
tries where the cost to compete is
high Frost says the magnitude of
the existing global installed base will
strengthen the need for replacement
and upgrades adding to market de-
mand as well
Frost says despite the potential
in developing economies the focus
on price as a product differentiator
may lead to intense price pressures
among manufacturers and bring down
the value of the overall market in the
short term The growing trend among
consumers to choose low-cost Chinese
imports will complicate this challenge
As price and quality become stan-
dardized across the globe customers
will base more of their purchasing deci-
sions on value-added services accord-
ing to Frost This will push manufactur-
ers to create more maintenance-free
solutions such as lubrication-free
bearings that offer end-users savings
on service and replacement costs and
reduce downtimeldquoOffering a complete line of prod-
ucts with comprehensive services will
be another feather in the cap of ven-
dors looking to widen their consumer
baserdquo notes Frost Industrial Automa-
tion and Process Control Research
Analyst Guru Mahesh
Moore says the trend of outsourcing
manufacturing to regions where labor
and production costs are favorable is
becoming less of a factor
ldquoThe days when cheap labor made
a significant difference in where a prod-
uct is manufactured mdash particularly high
value-added products or high weight
and bulk products mdash are coming to
an end as the cost of transportation
storage and inventory balance out the
benefits of production costs where la-
bor is a smaller percentage of the cost
of manufacturingrdquo Moore says ldquoLocal
manufacturing development will indeed
come to developing countries as their
ability to create markets that generate
economies of scale that support local
production is a clear trend and one that
all manufacturers will pay attention tordquo
Moore says that development of
maintenance-free or predictive tech-
nologies and products will be a sig-
nificant advantage to everyone in the
Bearing amp Coupling Manufacturers Focus
onDEVELOPING Economies
amp EFFICIENCY InnovationBy Amy W Richardson
2 January 2015
Flow Control Magazine
|
gy
Anew study from Frost amp Sullivan (wwwfrostcom) fore-
casts steady growth for the overall bearings and couplings
market based on rapid industrial development in high-growth
regions Specifically Frost predicts development in Mexico
Indonesia Nigeria Turkey Brazil Russia India and Chinawill help boost the bearings amp couplings market from $2206
billion in 2013 to an estimated $2676 billion in 2018
The development of maintenance-freeor predictive technologies will helpboost growth in the bearings market For example SKF is developing products that will automatically notifyusers when a bearing or mechanicalrotating component is approachingthe end of its useful life Pictured hereis an SKF Microlog analyzer a por- table condition monitoring tool
COURTESY SKF
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
improved productivity through simplified solutions The powerful technology and tools ensure repeatable
reliable accurate measurements Easier access to process data allows for better troubleshooting process
optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
For daily product notes visit the lsquoFeatured Productsrsquo section flowcontrolnetworkcom
ON THE WEB
1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3845
FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
and benefits as well as grids of
instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
services provided for the
mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
Brought to you by Beamex
Your Source For Fluid Handling Videos
Go towwwflowcontrolnetworkcomfreeinfo
Select appropriate issue ofFlow Control Magazine
Select advertisements thatinterest you
Enter your email amp clickldquoSubmit Requestrdquo
1
2
3
4
PRODUCT
INFORMATION
ONLINE
Follow these 4 steps to receive freeproduct information from suppliers
FREE
FEATURED VIDEO How to Calibrate aPressure Measurement Loop
For more information about FlowTube
sponsor packs email FlowControlGrandViewMediacom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4245
THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
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Title _________________________________________________________________
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______________________________________________________________________
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One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
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7232019 Flow Control January 2015
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PPLICATION NOTES | Flow Measurement
22 | January 2015
Flow Control Magazine
Gas flowmeters measure the actual volume of gas passing
through the meter per minute irrespective of pressure and
temperature1
The volumetric flowrate of a gas is often corrected to
ldquostandardizedrdquo conditions of pressure and temperature While
ldquostandardrdquo conditions can vary depending on the definition
in the US this typically means a pressure of 1473 PSIA(pounds per square inch absolute) and a temperature of 60 F
The flowrate measurement is reported in standard cubic feet
per minute (SCFM)
Compensating for changes in pressure and temperature is
critical Consider a meter system setup for flowing conditions
of 60 PSIG (pounds per square inch gauge) and 60 F and the
line pressure decreases to 50 PSIG while the temperature
remains constant The difference in SCFM between the two
is more than 15 percent which would cost the buyer more
for the gas than it should As Table 1 demonstrates even a
small variation in pressure will result in a surprisingly high er-
ror percentage
Automation of the K-Factor The K-factor is established by an initial factory calibration In
the case of a non-compensated flow monitor any variations
in pressure and temperature will result in manual adjust-
ments needed to the K-factor In order to maintain accurate
flow measurement users must monitor pressure and temper-
ature and make corresponding adjustments to the K-factor To eliminate these manual adjustments some suppliers offer
a flow monitor that automatically adjusts for any changes in
pressure and temperature
These monitors provide accurate flow measurement regard-
less of changing environmental conditions in some cases sup-
porting applications with pressures as high as 15000 PSIG and
temperatures between -350 F to 350 F with a standard accura-
cy of +-1 percent over a flow range of 05 ACFM to 650 ACFM
Final NotesDuring the operation of a flowmeter system the ability to obtain
a readout mdash and to adjust for line pressure and temperaturechanges mdash is sometimes compromised by a lack of electric
power This issue is especially true along gas pipelines in remote
areas To overcome this limitation some manufacturers have
designed low-powered flow monitors which can operate for up
to on year on a single lithium D-cell battery
It is important for users to recognize the effects of the
compressibility of gas As such the quantity of a gas flow-
ing through a gas flowmeter depends on the pressure and
temperature In order to ensure accuracy any flowmetering
system must employ a means to correct for these effects
Otherwise the readout is certain to be in error and could be
unnecessarily costing money This is particularly crucial onwellhead production and in billing scenarios FC
wwwturbinesincorporatedcom
Notations1 The measurement factor in the US is known as the
ACFM actual cubic feet per minute (Metric units are typically
ACMH actual cubic meters per hour)
Table 1 Error induced by line pressure changes
Constant Temperature with Varying Pressure
Pressure Temperature PulsesSCF Error
50 60 2556027821 1546
51 60 2517123288 1370
52 60 2479385307 1199
53 60 2442762186 1034
54 60 240720524 873
55 60 237266858 717
56 60 2339108911 566
57 60 2306485356 418
58 60 2274759285 275
59 60 2243894166 136
60 60 2213855422 000
61 60 2184610304 132
62 60 2156127771 261
63 60 2128378378 386
64 60 210133418 508
65 60 2074968632 627
66 60 2049256506 743
67 60 2024173807 857
68 60 1999697703 967
69 60 1975806452 1075
70 60 1952479339 1181 Flow Measurement | K-Factor | Measurement
Accuracy | Turbine Flowmeter
Find related content flowcontrolnetworkcomhellipSearch on
FLOWSTREAM
Kevin Clark is senior develop-
ment engineer for Turbines Research
amp Development LLC Turbine RampD is a
subsidiary and the research and techni-
cal support arm of Turbines Inc which
serves a range of industries and applica-
tions from oil amp gas to cryogenic liquids
to custody transferKevin Clark
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2645
Pumps Bearings amp Seals TECHNOLOGY REPORT
FEATURES
SYSTEMS DESIGN
The ComplicatedCase of
Compressors
withSide-Streams
24 28 32BEST PRACTICES
How PumpingSystems
AffectSealing
Performance
TECH OUTLOOK
BearingSuppliers
Drive Gains InDeveloping
Markets
wwwflowcontrolnetworkcom January 2015 | 23
S P E C I AL S E C T I O N
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2745
The design and operation of compressors with side-
streams has always been difficult because flow entering the
compressor needs to be mixed with the core flow already
in the compressor (compressed in section-1) in a manner
that does not degrade the aerodynamic performance of sur-
rounding sections Minimizing losses and ensuring proper
mixing of the side-stream flow and core-flow are required to
ensure effective performance of a compressor of this sort
Key considerations for an application involving compres-
sors with side-stream flow include
The plant process typically dictates the side-stream
flange pressure
The impellers upstream of the side-stream should
achieve the necessary pressure for the core-flow
The side-stream flow is typically at a temperature dif-
ferent from compressor core-flow temperature
Process plants need some degree of operational flex-
ibility ie the ability to support variations in core-flow condi-
tions and side-stream conditions
Modern process plants are usually specifying more than
one operating conditions (sometimes two or more manda-
tory conditions) which can present challenges to compres-
sors with side-streams Adding to these issues modern
compressors should operate with much higher impeller tip
The COMPLICATED CASE ofCompressors with Side-StreamsConsidering key system design requirements
to ensure operational efficiency By Amin Almasi
4 January 2015
Flow Control Magazine
|
y
g
Some compressors in certain applications
have one or more incoming side-streams
(or side-loads) that introduce side-stream
flow to mix with the core flow In other words
a radial side-stream inlet is utilized in multi-
impeller centrifugal compressors to introduce
additional gas into the mid-stage of a com-
pressor This design enables optimization in
some process plants However the flow dis-
tribution after the junction of the side-stream
and the main return channel of the upstream
section can significantly affect the perfor-mance of the next section of compressor
In most cases the pressure levels at these
side-streams should be accurately predicted
to meet the theoretical performance
Compressor station at a natural gas processing plant
R U D M E R Z W E R V E R I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2845
speeds and inlet Mach numbers compared to previous
generations of compressor technology
Likewise side-streams are now com-
monly used with medium-sized and
large-sized compressors (eg 1ndash60
MW) The costs associated with cor-
rections on side-stream compres-
sor applicationsmdashany repair
inefficient operation and power
lossesmdashwould be very high Fur-
ther compressors with side-streams
are usually sensitive and difficult
machines to operate In particular
performance curves (performance
pressures efficiency etc) are sen-
sitive to suction inlet conditionsside-stream inlet conditions vol-
ume flow ratio (side-stream vol-
ume to core-flow volume) and side-stream losses
Compressors with side-stream often perform far below
expectations The main reason is that side-stream compres-
sors are different than conventional compressors (without
a side-stream) in design and operation For a compressor
with side-streams tighter tolerances in operating conditions
must be identified and applied Uncontrolled variations of
suction pressure or side-stream pressure are major prob-
lems Another major issue is the variations of the flow ratio
(side-stream flow to core-flow)
Compressor Side-Stream amp Mixing SectionIn many centrifugal compressors the portion of the side-
stream system from the flange connection to the mixing
section is similar to a compressor inlet A great challenge
is ensuring the mixing section provides circumferentially
uniform merged-flow with minimum losses This can be
achieved via effective design of the inlet configuration and
mixing section of the side-stream compressor such that
the impeller can be maintained over the whole operating
range of the compressor In many cases while there are
mixing sections provided for the machine the flows do not
completely mix before entering the impeller of the section-2
(the impeller after the mixing section) Non-uniformity at
inlet flow to the impeller is a key concern for compressor
performance
Another consideration is a compact design of the side-
stream mixing section Specifically a mixing section with
less axial length is always preferred This axial length can af-
fect the compressor rotor dynam-
ics the rotor length and over-
all compressor performance
(design cost operation and
reliability)
The side-stream exit pressure
(side-stream pressure at inlet
of the mixing section) is mainly
a function of the side-stream
flow velocity and the pres-
sure in the previous section of
the compressor Conversely the side-
stream flange pressure can depend on
side-stream flow velocity and section-1
exit conditions Therefore the side-stream
inlet flange volume flow is a function of theflange pressure compressibility (at that
pressure and temperature) and mass flow
Some engineers assume that the side-stream flange pres-
sure is equal to the inlet pressure of the first impeller of the
section-2 This is not true The mixed total pressure can be
estimated on a mass-averaged basis using side-stream total
pressure and return channel exit (section-1) total pressure
In some designs because of the lower static pressure at
the side-stream exit the total pressure at the return channel
exit is lower even though the velocity upstream is roughly
matched for both streams The pressure usually increased
at the returned channel but it can be reduced again at the
side-stream exit While simple in nature this can have an
impact on the prediction of pressure at the side-stream exit
and overall mixing section performance Based on basic flow
principles it was usually assumed that the static pressure
was equal between both flow streams at the mixing location
While this assumption might be used in rough calculations
the accurate simulations have shown this assumption is not
true In fact there are some points (for instance the shroud
wall at the exit of the return channel and the hub wall at
the exit of the side-stream) where this assumption is true
However this is not valid for all locations There are pressure
changes that occur from a side-stream flange to the inlet
of the next section (section-2) which depend on different
factors The first factor is the frictional losses due to side-
stream geometry from side-stream flange to plenum mix-
ing section etc The other factors are pressure changes due
to local curvature and geometry details of mixing section
Another consideration is the operation of a compressor
with side-stream at part-load The performance of the side-
wwwflowcontrolnetworkcom January 2015 25
Figure 1 An example of a centrifugalcompressor with side-stream
COURTESY SIEMENS
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 29456 January 2015
Flow Control Magazine
|
y
g
stream path the mixing section and
the downstream impellers when ma-
chine is operated at part-load or even
off-design operating flows will result
in additional compressor performance
problems In such a case both veloc-
ity profiles and pressure variations in
various parts (side-stream path mixing
section etc) will be different resulting
in complicated flow patterns and com-
plex aerodynamics behaviors
Side-Stream CompressorSectional Performance
Typically vendor-supplied compressor
performance curves reflect flange-to-flange performance because that is
what the plant engineers need to
evaluate the proper operation of their
system (for example from suction to
side-stream and from side-stream to
discharge) In many cases compres-
sor vendors also provide the over-
all compressor performance curves
and performance curves for section-1
(from suction to side-stream) and sec-
tion-2 (from side-stream to discharge)
Flange-to-flange data if not interpret-
ed properly can lead to false conclu-
sions about the relative performance
of individual sections of a compression
system For example if side-stream
losses from the flange to mixing sec-
tion are attributed to the downstream
section (section-2) it will cause the
downstream section (section-2) to
appear low in performance while the
upstream section (section-1) will show
high performance levels
An important behavior to con-
sider is when the actual side-stream
pressure is different than the rated
side-stream pressure When the side-
stream pressure is slightly higher than
the outlet pressure of the section-1
it (section-1) shows a relatively higher
performance compared to the real sec-
tion-1 performance In some cases
the performance of section-1 could be
considerably higher than section-2 In
other words when performance is de-
termined flange to flange the higher
flange pressure is seen as extra ldquopseu-
dordquo work done by the section (since this
is an inconsistent thermodynamic vol-
ume) resulting in a relatively high sec-
tional efficiency (section-1 shows a rel-
atively high efficiency) This is the case
for many compressors with side-stream
because the whole system is designed
(or specifically the side-stream location
is selected) in a way aimed at main-
taining the real side-stream pressure(side-stream inlet) above the section-1
outlet pressure because if the real side-
stream pressure becomes lower than
the section-1 outlet pressure the flow
may (theoretically) reverse
This is particularly important when
the side-stream mass flow is much
lower than the mass flow of core-flow
The above-mentioned reasons explain
why in many simulations calcula-
tions and performance reports related
to compressors with side-stream the
section-1 shows a relatively good ef-
ficiency and section-2 appears low in
efficiency
When the side-stream pressure is
slightly lower than the outlet pressure
of the section-1 the section-1 might
show a relatively lower performance
compared to section-2 This could oc-
cur in some recycle services where the
side-stream is actually a recycle flow
with a mass flow around two to five
times the core-flow The side-stream
(recycle) flow is returned from down-
stream of the compressor to be slightly
compressed and recycled to the down-
stream Such a recycled side-stream
compressor can present unique chal-
lenges for design and operation This
kind of machine usually needs very
special operating procedures and very
fine adjustments regarding operating
pressures and flows
Side-Stream Compressor
Performance amp Operation An important consideration is the sen-
sitivity of compressor overall perfor-
mance curve and sectional perfor-
mance curves to the flow ratio (ratio
of side-stream flow to core-flow) and
to the inlet conditions Variations in
the flow and pressure of the main
suction and side-stream inlet should
be controlled within tight tolerances
For compressors with side-stream the ASME PTC-10 code stipulates limits on
flow ratio (side-stream volume to core-
flow volume) The acceptable variation
in volume flow ratio in a compressor
with a side-stream is +-5 percent as
per ASME PTC code The requested
side-stream pressure tolerance is not
usually specified in compressor codes
but it should be around +- 2 percent
(or sometimes +- 25 percent)
Variance in flow ratio impacts the
velocity levels where the two streams
merge Significant variation in the ve-
locity profile upstream of the impeller
changes the incidence on the blade
leading edge of the following impel-
ler This change in incidence leads to a
change in sectional performance over-
all compressor performance and train
efficiency
If the flow ratio is varied between 95
percent and 105 percent (tolerances
specified in the ASME PTC-10 code)
the flange pressure changes accord-
ingly resulting in a change in the sec-
tional performance and overall perfor-
mance The sectional efficiency varies
sometimes more than +- 4 percent
This variance reduces as the flow is de-
creased toward surge However as the
flow is increased toward overload the
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3045wwwflowcontrolnetworkcom January 2015 27
variance increases up to higher values
(even in some cases three to five times
compared to variations near the surge
zone) For example in a case study
for a compressor with side-streams a
+- 5 percent variation in flow ratio and
associated changes (pressures losses
etc) the sectional efficiency reduced by
approximately 34 percent at the rated
flow at allowable operating points at
the end of curve (near the overload
ie choke) efficiency reduced by ap-
proximately 55 percent These results
show that the variation in sectional
performance and overall performance
due to flow ratio is highest at operat-ing points near the overload and low-
est at operating points near the surge
For compressors which work most of
the time at high flow (flow higher than
rated flow and discharge pressure low-
er than rated pressure) the effects of
flow ratio deviations (and subsequently
efficiency reduction) would be higher
than compressors working on the left-
hand side of curve (say with sufficient
margins near the surge)
In the compressor codes (such as
API 617) the compressor power varia-
tions should be maintained below 4
percent However in some applica-
tions clients require tighter tolerances
on the consumed power sometimes
below 2 percent (or even below 15
percent) Some studies suggest while
+- 5 percent of volume flow ratio is
suitable for performance test as per
ASME PTC-10 code some plants re-
quire tighter control on the consumed
power and compressor performance
(lower limits on the efficiency) the tol-
erances on the volume flow ratio could
be tighter than ASME PTC code In this
regard +- 4 percent tolerance can be
suggested on the volume flow ratio (ra-
tio of side-stream flow to core-flow) of
compressors with side-streams
Based on operational experiences
acceptable variations in volume flow
ratio and inlet pressures (suction inlet
and side-stream inlet) of a compressor
with side-streams are +- 4 percent
and +- 2 percent respectively
Another important consideration is
the required adjustments for the flow
ratio (side-stream flow to core-flow)
Compressors with side-stream usually
require fixed side-stream flange pres-
sures For a compressor with some variations in operation conditions (even
small changes) it is not usually pos-
sible to achieve optimum operation by
keeping the flow ratio (side-stream to
core-flow) constant The flow ratio has
to be adjusted according to the inlet
flow at which the machine is operating
in order to get the required correspond-
ing side-stream flange pressure
Thermal changes have also been
known to cause some instability in
centrifugal compressors An example is
the thermal-induced change of resid-
ual unbalance For compressors with
side-streams which feature tempera-
ture differences between core-flow and
side-stream flow the thermal behav-
ior of the compressor is usually more
complex and requires more attention
Heavy Gas ChallengeHeavy gases (such as heavy hydrocar-
bon gases eg propane propylene
MTBE (Methyl Tertiary Butyl Ether))
have very low gas sonic velocities that
produce high Mach numbers in the
aerodynamic flow paths For these
services because of high Mach num-
ber high flow coefficient stages have
very narrow flow maps characterized
by limited surge and choke margins
Compressors with side-streams in
these services present great challeng-
es This is to say the side-streams and
associated mixing further complicate
design operation and performance
prediction because the pressure tem-
perature and flow conditions at each
one of these side-streams as well
as at the exit of the machine require
stringent tolerances to optimize the
overall efficiency and performance
As such it is important to accuratelymodel design operate and moni-
tor performance characteristics of any
impellers diffusers return channels
and generally all flow-path components
in a compressor with side-stream FC
Amin Almasi
is a senior rotating
machine consultant
in Australia He is
a chartered profes- sional engineer of
Engineers Australia
(MIEAust CPEng ndash
Mechanical) and
IMechE (CEng MIMechE) holds
bachelorrsquos and masterrsquos degrees
in Mechanical Engineering and is
a registered professional engineer
in Queensland He specializes in
rotating machines including cen-
trifugal screw and reciprocating
compressors gas turbines steamturbines engines pumps subsea
offshore rotating machines LNG
units condition monitoring and reli-
ability Mr Almasi is an active mem-
ber of Engineers Australia IMechE
ASME and SPE He can be reached
at aminalmasiymailcom
Amin Almasi
Compressor | Gas Flow | Performance Curve | Side-Stream Flow
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3145
The pressure in the stuffing box
containing the packing can be estimat-
ed by the following equation
SBP = [Discharge ndash Suction] 3 + Suction
Pressure at the bottom of the stuff-
ing box will be higher than the suction
pressure but considerably lower than
the discharge pressure It should be
noted this calculation will yield a con-
servative estimate of stuffing box pres-
sure that can be further reduced by
pump design
A hole in the stuffing box serves as
a port for injecting clean fluid that cir-
culates around a lantern ring aligned
under the flush port The fluid flushes
solids back into the process to protect
the packing from abrasive wear If the
clean fluid is injected at a pressure ex-
ceeding that at the bottom of the stuff-
ing box some of it will leak back into
the process and some will leak out to
the atmosphere Recommended flush
injection pressure is 15ndash30 PSI (1ndash2
Bar) greater than the pressure at the
bottom of the stuffing box
Fluid injection is also used to lubri-
cate and cool dry-running packing that
is subject to frictional heat and to pre-
vent air from entering the pump which
reduces flow and operating efficiency
Centrifugal pumps utilize three
types of impellersmdashopen semi-open
and closed (Figures 2 3 amp 4) Open
designs prevent fluids with large solids
from clogging the impellers but at theexpense of pump efficiency Backing
plates on semi-open designs serve to
trap the fluid for more efficient opera-
tion Closed impellers are for use with
clean fluids since solids could ac-
cumulate in the eye which would re-
quire tearing down the pump to remove
them
Single-Stage CentrifugalPumpsSingle-stage centrifugal pumps typi-
cally have good bearing support of the
shaft with few run-out or ldquowhiprdquo prob-
lems However in some cases they
are subject to cavitation This occurs
in the eye of the impeller where the
fluid is under vacuum If the pressure
is low enough it will cause the material
to vaporize forming air or water vapor
bubbles As the fluid passes through
How Pumping Systems Design Affects Sealing Performance
By Chris Boss
8 January 2015
Flow Control Magazine
|
Understanding how different types of pump designs impact
sealing is critical to optimizing efficiency safety and lon-
gevity of the sealing system Used for a wide variety of media
including clear fluids solutions and slurries single-stage
centrifugal pumps are one of the most common
types (Figure 1) Fluid drawn into these pumps
enters the eye of an impeller that spins itto the outside of its container
or volute building pressure as
it moves toward discharge
Some of this fluid will work
its way behind the impeller
where it must be sealed with
compression packing or a
mechanical seal
Figure 1
Figure 2 Figure 3 Figure 4
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3245
the pump under increasing pressure
these bubbles implode sending shock
and vibration through the impeller
adversely affecting the seal This phe-
nomenon can be mitigated by running
the pump at slower speed and higher
pressure at the suction end to prevent
air from entering the fluid
Double-Ended Split-CasePumpsOperating on the same centrifugal prin-
ciple but slightly different geometry are
double-ended split-case pumps (Figure
5) Fluid enters both ends of the pump
and is directed into the eye of an impel-ler which spins it out of the volute to
discharge Packing is installed on both
the shaft and bearing ends so the stuff-
ing box is exposed only to suction pres-
sure which is usually quite low
Axial Flow Pumps Axial flow pumps operate like hydro
turbines in reverse whereby a propeller
(or axial impeller) pushes the fluid to
discharge (Figure 6)
Since the stuffing box is located
downstream of the propeller at the dis-
charge end of the pump the packing is
exposed to the full discharge pressure
Vertical PumpsVertical turbine pumps are typically
flange-mounted on a floor extending
downward into a water-filled sump
hole (Figure 7) Available as single- or
multi-stage pumps they feature an
impeller or series of impellers rotated
simultaneously by a single shaft The
impellers increase the pressure of the
upward flow subjecting the stuffing box
to full discharge pressure
Vertical pumps can be quite long so
inadequate bearing support can cause
the shaft to run out This can induce
undesirable lateral motion on the pack-
ing Worse the packing may be forced
to serve both as a bearing and a seal To
withstand these conditions the packing
should be resilient elastic and resistant
to deformation These properties rule
out packing such as graphite foil in favor
of fiber-based materials
Multi-Stage PumpsMulti-stage pumps are used for high-
pressure applications such as feeding
the boilers in steam-powered generating
plants Stuffing box pressure can vary
with pump design and number of stag-
es Designed for clean fluids and high
operating speeds these pumps typically
have high- and low-pressure ends with ahydraulic pressure equalization line run-
ning between the stuffing boxes
Like vertical pumps multi-stage
pumps feature a series of impellers to
build fluid discharge pressure In the
case of the six-stage pump pictured in
Figure 8 fluid enters at the drive end
where a stuffing box is exposed to suc-
tion pressure Channeled from one
impeller to the next through the pump
casting the fluid can reach extremely
high pressures at discharge
A second stuffing box located at the
bearing end is exposed to an intermedi-
ate pressure from the third impeller This
pressure is greater than the suction pres-
sure but much less than the discharge
pressure which can reach 2000 PSI
Fortunately the stuffing boxes in
these pumps are not exposed to dis-
charge pressures and typically see be-
low 500 PSI which is within the range
of some packing materials
wwwflowcontrolnetworkcom January 2015 29
Figure 5
Figure 6
Figure 7
Figure 8
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 33450 January 2015
Flow Control Magazine
| Gear PumpsPositive-displacement or gear pumps
operate on a different principle than
centrifugal pumps In external gear
pumps the fluid flows around the out-
side of the gears the intermeshing
of which forces it through the pump
to discharge (Figure 9) This design
makes these pumps particularly suit-
able for use with highly viscous fluids
such as resins emulsions syrups and
adhesives As such they are used for
transfer or metering applications
It should be noted gear pumps will
continue to displace fluid as long as
their shafts are turning which can pose
a problem if a clog occurs at the dis-
charge The resulting buildup of pres-
sure can blow out seals and damage
the pump Therefore most gear pumps
have pressure relief valves to divert
fluid back to the suction side for re-
circulation through the pump Internal
gear pumps operate slightly differently
but also have pressure relief valves to
prevent damage from excessive pres-
sure (Figure 10) In both external and
internal gear pumps the maximum
stuffing box pressure is determined by
these valves
Other rotating equipment includes
mixersagitators which are similar to
pumps in terms of the speeds to which
the packing is exposed There are ba-
sically three types of mixersagitators
top- bottom- and side-entry Top-entry
models are subject to the same con-
cerns about shaft run-out ldquowhiprdquo and
lateral forces on the paddles that are
encountered in some vertical pumps
Although some fluid may splash onto
the packing these mixers basically run
dry so the packing must have the abil-
ity to dissipate the resulting frictional
heat
In bottom-entry mixers the packing
is always exposed to fluid and may also
be exposed to solids requiring abra-
sion-resistance If the seal fails the en-
tire contents of the tank will eventually
drain out onto the bearings the floor
and other components under the stuff-
ing box
The packing in side-entry mixers may
be fully or intermittently exposed to flu-
id as well as side loading and vibration
Aside from media temperature
speed and other application variables
the configurations and operating prin-
ciples of rotary-type pumps exert differ-
ent forces on the seals used to keep
them from leaking These forces can
spell the difference between accept-
able seal performance and failure
Understanding these differences has
important implications that should be
taken into account to assure proper
sealing selection for long-term trou-
ble-free performance FC
wwwgarlockcom
Chris Boss is
a senior applica-
tions engineer for
Garlock Sealing
Technologies in
Palmyra NY He
has held various
positions in produc-
tion engineering
product development and applica-
tions engineering for the companyrsquos
compression packing division He
is a BSME graduate of the State
University of New York at Buffalo Mr
Boss can be reached at 800 448-
6688 or chrisbossgarlockcom
Chris Boss
Cavitation | Centrifugal Pump | Pump Packing | Sealing System
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Figure 9
Figure 10
Aside from media temperature speed and
other application variables the configurations
and operating principles of rotary-type
pumps exert different forces on the seals used
to keep them from leaking These forces can
spell the difference between acceptable seal
performance and failure
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3445
NS IDERNDUSTRIAL AUTOMATION + PROCESS CONTROL
WANT
INFORMATION
ON THE
automationindustry
SUBSCRIBE NOW at wwwiainsidercouk
Published by Spitzer and Boyes LLC Write in 15 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
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Frost says the push from developing
economies is important as the market
is technologically mature and seeing
restricted growth in developed econo-
mies This is particularly true in Europe
and North America where recent finan-
cial insta-
bility has
reduced capital expenditure across end-
user industries
Bill Moore senior vice president of
sales development and channel man-
agement for global bearings manufac-
turer SKF says ldquosmartrdquo products and
the expansion of robust reliability pro-
grams are helping to drive new invest-
ment particularly in developed coun-
tries where the cost to compete is
high Frost says the magnitude of
the existing global installed base will
strengthen the need for replacement
and upgrades adding to market de-
mand as well
Frost says despite the potential
in developing economies the focus
on price as a product differentiator
may lead to intense price pressures
among manufacturers and bring down
the value of the overall market in the
short term The growing trend among
consumers to choose low-cost Chinese
imports will complicate this challenge
As price and quality become stan-
dardized across the globe customers
will base more of their purchasing deci-
sions on value-added services accord-
ing to Frost This will push manufactur-
ers to create more maintenance-free
solutions such as lubrication-free
bearings that offer end-users savings
on service and replacement costs and
reduce downtimeldquoOffering a complete line of prod-
ucts with comprehensive services will
be another feather in the cap of ven-
dors looking to widen their consumer
baserdquo notes Frost Industrial Automa-
tion and Process Control Research
Analyst Guru Mahesh
Moore says the trend of outsourcing
manufacturing to regions where labor
and production costs are favorable is
becoming less of a factor
ldquoThe days when cheap labor made
a significant difference in where a prod-
uct is manufactured mdash particularly high
value-added products or high weight
and bulk products mdash are coming to
an end as the cost of transportation
storage and inventory balance out the
benefits of production costs where la-
bor is a smaller percentage of the cost
of manufacturingrdquo Moore says ldquoLocal
manufacturing development will indeed
come to developing countries as their
ability to create markets that generate
economies of scale that support local
production is a clear trend and one that
all manufacturers will pay attention tordquo
Moore says that development of
maintenance-free or predictive tech-
nologies and products will be a sig-
nificant advantage to everyone in the
Bearing amp Coupling Manufacturers Focus
onDEVELOPING Economies
amp EFFICIENCY InnovationBy Amy W Richardson
2 January 2015
Flow Control Magazine
|
gy
Anew study from Frost amp Sullivan (wwwfrostcom) fore-
casts steady growth for the overall bearings and couplings
market based on rapid industrial development in high-growth
regions Specifically Frost predicts development in Mexico
Indonesia Nigeria Turkey Brazil Russia India and Chinawill help boost the bearings amp couplings market from $2206
billion in 2013 to an estimated $2676 billion in 2018
The development of maintenance-freeor predictive technologies will helpboost growth in the bearings market For example SKF is developing products that will automatically notifyusers when a bearing or mechanicalrotating component is approachingthe end of its useful life Pictured hereis an SKF Microlog analyzer a por- table condition monitoring tool
COURTESY SKF
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
improved productivity through simplified solutions The powerful technology and tools ensure repeatable
reliable accurate measurements Easier access to process data allows for better troubleshooting process
optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
For daily product notes visit the lsquoFeatured Productsrsquo section flowcontrolnetworkcom
ON THE WEB
1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3845
FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
and benefits as well as grids of
instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
services provided for the
mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
Brought to you by Beamex
Your Source For Fluid Handling Videos
Go towwwflowcontrolnetworkcomfreeinfo
Select appropriate issue ofFlow Control Magazine
Select advertisements thatinterest you
Enter your email amp clickldquoSubmit Requestrdquo
1
2
3
4
PRODUCT
INFORMATION
ONLINE
Follow these 4 steps to receive freeproduct information from suppliers
FREE
FEATURED VIDEO How to Calibrate aPressure Measurement Loop
For more information about FlowTube
sponsor packs email FlowControlGrandViewMediacom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4245
THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
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______________________________________________________________________
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One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
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![Page 26: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/26.jpg)
7232019 Flow Control January 2015
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Pumps Bearings amp Seals TECHNOLOGY REPORT
FEATURES
SYSTEMS DESIGN
The ComplicatedCase of
Compressors
withSide-Streams
24 28 32BEST PRACTICES
How PumpingSystems
AffectSealing
Performance
TECH OUTLOOK
BearingSuppliers
Drive Gains InDeveloping
Markets
wwwflowcontrolnetworkcom January 2015 | 23
S P E C I AL S E C T I O N
I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2745
The design and operation of compressors with side-
streams has always been difficult because flow entering the
compressor needs to be mixed with the core flow already
in the compressor (compressed in section-1) in a manner
that does not degrade the aerodynamic performance of sur-
rounding sections Minimizing losses and ensuring proper
mixing of the side-stream flow and core-flow are required to
ensure effective performance of a compressor of this sort
Key considerations for an application involving compres-
sors with side-stream flow include
The plant process typically dictates the side-stream
flange pressure
The impellers upstream of the side-stream should
achieve the necessary pressure for the core-flow
The side-stream flow is typically at a temperature dif-
ferent from compressor core-flow temperature
Process plants need some degree of operational flex-
ibility ie the ability to support variations in core-flow condi-
tions and side-stream conditions
Modern process plants are usually specifying more than
one operating conditions (sometimes two or more manda-
tory conditions) which can present challenges to compres-
sors with side-streams Adding to these issues modern
compressors should operate with much higher impeller tip
The COMPLICATED CASE ofCompressors with Side-StreamsConsidering key system design requirements
to ensure operational efficiency By Amin Almasi
4 January 2015
Flow Control Magazine
|
y
g
Some compressors in certain applications
have one or more incoming side-streams
(or side-loads) that introduce side-stream
flow to mix with the core flow In other words
a radial side-stream inlet is utilized in multi-
impeller centrifugal compressors to introduce
additional gas into the mid-stage of a com-
pressor This design enables optimization in
some process plants However the flow dis-
tribution after the junction of the side-stream
and the main return channel of the upstream
section can significantly affect the perfor-mance of the next section of compressor
In most cases the pressure levels at these
side-streams should be accurately predicted
to meet the theoretical performance
Compressor station at a natural gas processing plant
R U D M E R Z W E R V E R I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2845
speeds and inlet Mach numbers compared to previous
generations of compressor technology
Likewise side-streams are now com-
monly used with medium-sized and
large-sized compressors (eg 1ndash60
MW) The costs associated with cor-
rections on side-stream compres-
sor applicationsmdashany repair
inefficient operation and power
lossesmdashwould be very high Fur-
ther compressors with side-streams
are usually sensitive and difficult
machines to operate In particular
performance curves (performance
pressures efficiency etc) are sen-
sitive to suction inlet conditionsside-stream inlet conditions vol-
ume flow ratio (side-stream vol-
ume to core-flow volume) and side-stream losses
Compressors with side-stream often perform far below
expectations The main reason is that side-stream compres-
sors are different than conventional compressors (without
a side-stream) in design and operation For a compressor
with side-streams tighter tolerances in operating conditions
must be identified and applied Uncontrolled variations of
suction pressure or side-stream pressure are major prob-
lems Another major issue is the variations of the flow ratio
(side-stream flow to core-flow)
Compressor Side-Stream amp Mixing SectionIn many centrifugal compressors the portion of the side-
stream system from the flange connection to the mixing
section is similar to a compressor inlet A great challenge
is ensuring the mixing section provides circumferentially
uniform merged-flow with minimum losses This can be
achieved via effective design of the inlet configuration and
mixing section of the side-stream compressor such that
the impeller can be maintained over the whole operating
range of the compressor In many cases while there are
mixing sections provided for the machine the flows do not
completely mix before entering the impeller of the section-2
(the impeller after the mixing section) Non-uniformity at
inlet flow to the impeller is a key concern for compressor
performance
Another consideration is a compact design of the side-
stream mixing section Specifically a mixing section with
less axial length is always preferred This axial length can af-
fect the compressor rotor dynam-
ics the rotor length and over-
all compressor performance
(design cost operation and
reliability)
The side-stream exit pressure
(side-stream pressure at inlet
of the mixing section) is mainly
a function of the side-stream
flow velocity and the pres-
sure in the previous section of
the compressor Conversely the side-
stream flange pressure can depend on
side-stream flow velocity and section-1
exit conditions Therefore the side-stream
inlet flange volume flow is a function of theflange pressure compressibility (at that
pressure and temperature) and mass flow
Some engineers assume that the side-stream flange pres-
sure is equal to the inlet pressure of the first impeller of the
section-2 This is not true The mixed total pressure can be
estimated on a mass-averaged basis using side-stream total
pressure and return channel exit (section-1) total pressure
In some designs because of the lower static pressure at
the side-stream exit the total pressure at the return channel
exit is lower even though the velocity upstream is roughly
matched for both streams The pressure usually increased
at the returned channel but it can be reduced again at the
side-stream exit While simple in nature this can have an
impact on the prediction of pressure at the side-stream exit
and overall mixing section performance Based on basic flow
principles it was usually assumed that the static pressure
was equal between both flow streams at the mixing location
While this assumption might be used in rough calculations
the accurate simulations have shown this assumption is not
true In fact there are some points (for instance the shroud
wall at the exit of the return channel and the hub wall at
the exit of the side-stream) where this assumption is true
However this is not valid for all locations There are pressure
changes that occur from a side-stream flange to the inlet
of the next section (section-2) which depend on different
factors The first factor is the frictional losses due to side-
stream geometry from side-stream flange to plenum mix-
ing section etc The other factors are pressure changes due
to local curvature and geometry details of mixing section
Another consideration is the operation of a compressor
with side-stream at part-load The performance of the side-
wwwflowcontrolnetworkcom January 2015 25
Figure 1 An example of a centrifugalcompressor with side-stream
COURTESY SIEMENS
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 29456 January 2015
Flow Control Magazine
|
y
g
stream path the mixing section and
the downstream impellers when ma-
chine is operated at part-load or even
off-design operating flows will result
in additional compressor performance
problems In such a case both veloc-
ity profiles and pressure variations in
various parts (side-stream path mixing
section etc) will be different resulting
in complicated flow patterns and com-
plex aerodynamics behaviors
Side-Stream CompressorSectional Performance
Typically vendor-supplied compressor
performance curves reflect flange-to-flange performance because that is
what the plant engineers need to
evaluate the proper operation of their
system (for example from suction to
side-stream and from side-stream to
discharge) In many cases compres-
sor vendors also provide the over-
all compressor performance curves
and performance curves for section-1
(from suction to side-stream) and sec-
tion-2 (from side-stream to discharge)
Flange-to-flange data if not interpret-
ed properly can lead to false conclu-
sions about the relative performance
of individual sections of a compression
system For example if side-stream
losses from the flange to mixing sec-
tion are attributed to the downstream
section (section-2) it will cause the
downstream section (section-2) to
appear low in performance while the
upstream section (section-1) will show
high performance levels
An important behavior to con-
sider is when the actual side-stream
pressure is different than the rated
side-stream pressure When the side-
stream pressure is slightly higher than
the outlet pressure of the section-1
it (section-1) shows a relatively higher
performance compared to the real sec-
tion-1 performance In some cases
the performance of section-1 could be
considerably higher than section-2 In
other words when performance is de-
termined flange to flange the higher
flange pressure is seen as extra ldquopseu-
dordquo work done by the section (since this
is an inconsistent thermodynamic vol-
ume) resulting in a relatively high sec-
tional efficiency (section-1 shows a rel-
atively high efficiency) This is the case
for many compressors with side-stream
because the whole system is designed
(or specifically the side-stream location
is selected) in a way aimed at main-
taining the real side-stream pressure(side-stream inlet) above the section-1
outlet pressure because if the real side-
stream pressure becomes lower than
the section-1 outlet pressure the flow
may (theoretically) reverse
This is particularly important when
the side-stream mass flow is much
lower than the mass flow of core-flow
The above-mentioned reasons explain
why in many simulations calcula-
tions and performance reports related
to compressors with side-stream the
section-1 shows a relatively good ef-
ficiency and section-2 appears low in
efficiency
When the side-stream pressure is
slightly lower than the outlet pressure
of the section-1 the section-1 might
show a relatively lower performance
compared to section-2 This could oc-
cur in some recycle services where the
side-stream is actually a recycle flow
with a mass flow around two to five
times the core-flow The side-stream
(recycle) flow is returned from down-
stream of the compressor to be slightly
compressed and recycled to the down-
stream Such a recycled side-stream
compressor can present unique chal-
lenges for design and operation This
kind of machine usually needs very
special operating procedures and very
fine adjustments regarding operating
pressures and flows
Side-Stream Compressor
Performance amp Operation An important consideration is the sen-
sitivity of compressor overall perfor-
mance curve and sectional perfor-
mance curves to the flow ratio (ratio
of side-stream flow to core-flow) and
to the inlet conditions Variations in
the flow and pressure of the main
suction and side-stream inlet should
be controlled within tight tolerances
For compressors with side-stream the ASME PTC-10 code stipulates limits on
flow ratio (side-stream volume to core-
flow volume) The acceptable variation
in volume flow ratio in a compressor
with a side-stream is +-5 percent as
per ASME PTC code The requested
side-stream pressure tolerance is not
usually specified in compressor codes
but it should be around +- 2 percent
(or sometimes +- 25 percent)
Variance in flow ratio impacts the
velocity levels where the two streams
merge Significant variation in the ve-
locity profile upstream of the impeller
changes the incidence on the blade
leading edge of the following impel-
ler This change in incidence leads to a
change in sectional performance over-
all compressor performance and train
efficiency
If the flow ratio is varied between 95
percent and 105 percent (tolerances
specified in the ASME PTC-10 code)
the flange pressure changes accord-
ingly resulting in a change in the sec-
tional performance and overall perfor-
mance The sectional efficiency varies
sometimes more than +- 4 percent
This variance reduces as the flow is de-
creased toward surge However as the
flow is increased toward overload the
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3045wwwflowcontrolnetworkcom January 2015 27
variance increases up to higher values
(even in some cases three to five times
compared to variations near the surge
zone) For example in a case study
for a compressor with side-streams a
+- 5 percent variation in flow ratio and
associated changes (pressures losses
etc) the sectional efficiency reduced by
approximately 34 percent at the rated
flow at allowable operating points at
the end of curve (near the overload
ie choke) efficiency reduced by ap-
proximately 55 percent These results
show that the variation in sectional
performance and overall performance
due to flow ratio is highest at operat-ing points near the overload and low-
est at operating points near the surge
For compressors which work most of
the time at high flow (flow higher than
rated flow and discharge pressure low-
er than rated pressure) the effects of
flow ratio deviations (and subsequently
efficiency reduction) would be higher
than compressors working on the left-
hand side of curve (say with sufficient
margins near the surge)
In the compressor codes (such as
API 617) the compressor power varia-
tions should be maintained below 4
percent However in some applica-
tions clients require tighter tolerances
on the consumed power sometimes
below 2 percent (or even below 15
percent) Some studies suggest while
+- 5 percent of volume flow ratio is
suitable for performance test as per
ASME PTC-10 code some plants re-
quire tighter control on the consumed
power and compressor performance
(lower limits on the efficiency) the tol-
erances on the volume flow ratio could
be tighter than ASME PTC code In this
regard +- 4 percent tolerance can be
suggested on the volume flow ratio (ra-
tio of side-stream flow to core-flow) of
compressors with side-streams
Based on operational experiences
acceptable variations in volume flow
ratio and inlet pressures (suction inlet
and side-stream inlet) of a compressor
with side-streams are +- 4 percent
and +- 2 percent respectively
Another important consideration is
the required adjustments for the flow
ratio (side-stream flow to core-flow)
Compressors with side-stream usually
require fixed side-stream flange pres-
sures For a compressor with some variations in operation conditions (even
small changes) it is not usually pos-
sible to achieve optimum operation by
keeping the flow ratio (side-stream to
core-flow) constant The flow ratio has
to be adjusted according to the inlet
flow at which the machine is operating
in order to get the required correspond-
ing side-stream flange pressure
Thermal changes have also been
known to cause some instability in
centrifugal compressors An example is
the thermal-induced change of resid-
ual unbalance For compressors with
side-streams which feature tempera-
ture differences between core-flow and
side-stream flow the thermal behav-
ior of the compressor is usually more
complex and requires more attention
Heavy Gas ChallengeHeavy gases (such as heavy hydrocar-
bon gases eg propane propylene
MTBE (Methyl Tertiary Butyl Ether))
have very low gas sonic velocities that
produce high Mach numbers in the
aerodynamic flow paths For these
services because of high Mach num-
ber high flow coefficient stages have
very narrow flow maps characterized
by limited surge and choke margins
Compressors with side-streams in
these services present great challeng-
es This is to say the side-streams and
associated mixing further complicate
design operation and performance
prediction because the pressure tem-
perature and flow conditions at each
one of these side-streams as well
as at the exit of the machine require
stringent tolerances to optimize the
overall efficiency and performance
As such it is important to accuratelymodel design operate and moni-
tor performance characteristics of any
impellers diffusers return channels
and generally all flow-path components
in a compressor with side-stream FC
Amin Almasi
is a senior rotating
machine consultant
in Australia He is
a chartered profes- sional engineer of
Engineers Australia
(MIEAust CPEng ndash
Mechanical) and
IMechE (CEng MIMechE) holds
bachelorrsquos and masterrsquos degrees
in Mechanical Engineering and is
a registered professional engineer
in Queensland He specializes in
rotating machines including cen-
trifugal screw and reciprocating
compressors gas turbines steamturbines engines pumps subsea
offshore rotating machines LNG
units condition monitoring and reli-
ability Mr Almasi is an active mem-
ber of Engineers Australia IMechE
ASME and SPE He can be reached
at aminalmasiymailcom
Amin Almasi
Compressor | Gas Flow | Performance Curve | Side-Stream Flow
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3145
The pressure in the stuffing box
containing the packing can be estimat-
ed by the following equation
SBP = [Discharge ndash Suction] 3 + Suction
Pressure at the bottom of the stuff-
ing box will be higher than the suction
pressure but considerably lower than
the discharge pressure It should be
noted this calculation will yield a con-
servative estimate of stuffing box pres-
sure that can be further reduced by
pump design
A hole in the stuffing box serves as
a port for injecting clean fluid that cir-
culates around a lantern ring aligned
under the flush port The fluid flushes
solids back into the process to protect
the packing from abrasive wear If the
clean fluid is injected at a pressure ex-
ceeding that at the bottom of the stuff-
ing box some of it will leak back into
the process and some will leak out to
the atmosphere Recommended flush
injection pressure is 15ndash30 PSI (1ndash2
Bar) greater than the pressure at the
bottom of the stuffing box
Fluid injection is also used to lubri-
cate and cool dry-running packing that
is subject to frictional heat and to pre-
vent air from entering the pump which
reduces flow and operating efficiency
Centrifugal pumps utilize three
types of impellersmdashopen semi-open
and closed (Figures 2 3 amp 4) Open
designs prevent fluids with large solids
from clogging the impellers but at theexpense of pump efficiency Backing
plates on semi-open designs serve to
trap the fluid for more efficient opera-
tion Closed impellers are for use with
clean fluids since solids could ac-
cumulate in the eye which would re-
quire tearing down the pump to remove
them
Single-Stage CentrifugalPumpsSingle-stage centrifugal pumps typi-
cally have good bearing support of the
shaft with few run-out or ldquowhiprdquo prob-
lems However in some cases they
are subject to cavitation This occurs
in the eye of the impeller where the
fluid is under vacuum If the pressure
is low enough it will cause the material
to vaporize forming air or water vapor
bubbles As the fluid passes through
How Pumping Systems Design Affects Sealing Performance
By Chris Boss
8 January 2015
Flow Control Magazine
|
Understanding how different types of pump designs impact
sealing is critical to optimizing efficiency safety and lon-
gevity of the sealing system Used for a wide variety of media
including clear fluids solutions and slurries single-stage
centrifugal pumps are one of the most common
types (Figure 1) Fluid drawn into these pumps
enters the eye of an impeller that spins itto the outside of its container
or volute building pressure as
it moves toward discharge
Some of this fluid will work
its way behind the impeller
where it must be sealed with
compression packing or a
mechanical seal
Figure 1
Figure 2 Figure 3 Figure 4
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3245
the pump under increasing pressure
these bubbles implode sending shock
and vibration through the impeller
adversely affecting the seal This phe-
nomenon can be mitigated by running
the pump at slower speed and higher
pressure at the suction end to prevent
air from entering the fluid
Double-Ended Split-CasePumpsOperating on the same centrifugal prin-
ciple but slightly different geometry are
double-ended split-case pumps (Figure
5) Fluid enters both ends of the pump
and is directed into the eye of an impel-ler which spins it out of the volute to
discharge Packing is installed on both
the shaft and bearing ends so the stuff-
ing box is exposed only to suction pres-
sure which is usually quite low
Axial Flow Pumps Axial flow pumps operate like hydro
turbines in reverse whereby a propeller
(or axial impeller) pushes the fluid to
discharge (Figure 6)
Since the stuffing box is located
downstream of the propeller at the dis-
charge end of the pump the packing is
exposed to the full discharge pressure
Vertical PumpsVertical turbine pumps are typically
flange-mounted on a floor extending
downward into a water-filled sump
hole (Figure 7) Available as single- or
multi-stage pumps they feature an
impeller or series of impellers rotated
simultaneously by a single shaft The
impellers increase the pressure of the
upward flow subjecting the stuffing box
to full discharge pressure
Vertical pumps can be quite long so
inadequate bearing support can cause
the shaft to run out This can induce
undesirable lateral motion on the pack-
ing Worse the packing may be forced
to serve both as a bearing and a seal To
withstand these conditions the packing
should be resilient elastic and resistant
to deformation These properties rule
out packing such as graphite foil in favor
of fiber-based materials
Multi-Stage PumpsMulti-stage pumps are used for high-
pressure applications such as feeding
the boilers in steam-powered generating
plants Stuffing box pressure can vary
with pump design and number of stag-
es Designed for clean fluids and high
operating speeds these pumps typically
have high- and low-pressure ends with ahydraulic pressure equalization line run-
ning between the stuffing boxes
Like vertical pumps multi-stage
pumps feature a series of impellers to
build fluid discharge pressure In the
case of the six-stage pump pictured in
Figure 8 fluid enters at the drive end
where a stuffing box is exposed to suc-
tion pressure Channeled from one
impeller to the next through the pump
casting the fluid can reach extremely
high pressures at discharge
A second stuffing box located at the
bearing end is exposed to an intermedi-
ate pressure from the third impeller This
pressure is greater than the suction pres-
sure but much less than the discharge
pressure which can reach 2000 PSI
Fortunately the stuffing boxes in
these pumps are not exposed to dis-
charge pressures and typically see be-
low 500 PSI which is within the range
of some packing materials
wwwflowcontrolnetworkcom January 2015 29
Figure 5
Figure 6
Figure 7
Figure 8
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 33450 January 2015
Flow Control Magazine
| Gear PumpsPositive-displacement or gear pumps
operate on a different principle than
centrifugal pumps In external gear
pumps the fluid flows around the out-
side of the gears the intermeshing
of which forces it through the pump
to discharge (Figure 9) This design
makes these pumps particularly suit-
able for use with highly viscous fluids
such as resins emulsions syrups and
adhesives As such they are used for
transfer or metering applications
It should be noted gear pumps will
continue to displace fluid as long as
their shafts are turning which can pose
a problem if a clog occurs at the dis-
charge The resulting buildup of pres-
sure can blow out seals and damage
the pump Therefore most gear pumps
have pressure relief valves to divert
fluid back to the suction side for re-
circulation through the pump Internal
gear pumps operate slightly differently
but also have pressure relief valves to
prevent damage from excessive pres-
sure (Figure 10) In both external and
internal gear pumps the maximum
stuffing box pressure is determined by
these valves
Other rotating equipment includes
mixersagitators which are similar to
pumps in terms of the speeds to which
the packing is exposed There are ba-
sically three types of mixersagitators
top- bottom- and side-entry Top-entry
models are subject to the same con-
cerns about shaft run-out ldquowhiprdquo and
lateral forces on the paddles that are
encountered in some vertical pumps
Although some fluid may splash onto
the packing these mixers basically run
dry so the packing must have the abil-
ity to dissipate the resulting frictional
heat
In bottom-entry mixers the packing
is always exposed to fluid and may also
be exposed to solids requiring abra-
sion-resistance If the seal fails the en-
tire contents of the tank will eventually
drain out onto the bearings the floor
and other components under the stuff-
ing box
The packing in side-entry mixers may
be fully or intermittently exposed to flu-
id as well as side loading and vibration
Aside from media temperature
speed and other application variables
the configurations and operating prin-
ciples of rotary-type pumps exert differ-
ent forces on the seals used to keep
them from leaking These forces can
spell the difference between accept-
able seal performance and failure
Understanding these differences has
important implications that should be
taken into account to assure proper
sealing selection for long-term trou-
ble-free performance FC
wwwgarlockcom
Chris Boss is
a senior applica-
tions engineer for
Garlock Sealing
Technologies in
Palmyra NY He
has held various
positions in produc-
tion engineering
product development and applica-
tions engineering for the companyrsquos
compression packing division He
is a BSME graduate of the State
University of New York at Buffalo Mr
Boss can be reached at 800 448-
6688 or chrisbossgarlockcom
Chris Boss
Cavitation | Centrifugal Pump | Pump Packing | Sealing System
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Figure 9
Figure 10
Aside from media temperature speed and
other application variables the configurations
and operating principles of rotary-type
pumps exert different forces on the seals used
to keep them from leaking These forces can
spell the difference between acceptable seal
performance and failure
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3445
NS IDERNDUSTRIAL AUTOMATION + PROCESS CONTROL
WANT
INFORMATION
ON THE
automationindustry
SUBSCRIBE NOW at wwwiainsidercouk
Published by Spitzer and Boyes LLC Write in 15 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3545
Frost says the push from developing
economies is important as the market
is technologically mature and seeing
restricted growth in developed econo-
mies This is particularly true in Europe
and North America where recent finan-
cial insta-
bility has
reduced capital expenditure across end-
user industries
Bill Moore senior vice president of
sales development and channel man-
agement for global bearings manufac-
turer SKF says ldquosmartrdquo products and
the expansion of robust reliability pro-
grams are helping to drive new invest-
ment particularly in developed coun-
tries where the cost to compete is
high Frost says the magnitude of
the existing global installed base will
strengthen the need for replacement
and upgrades adding to market de-
mand as well
Frost says despite the potential
in developing economies the focus
on price as a product differentiator
may lead to intense price pressures
among manufacturers and bring down
the value of the overall market in the
short term The growing trend among
consumers to choose low-cost Chinese
imports will complicate this challenge
As price and quality become stan-
dardized across the globe customers
will base more of their purchasing deci-
sions on value-added services accord-
ing to Frost This will push manufactur-
ers to create more maintenance-free
solutions such as lubrication-free
bearings that offer end-users savings
on service and replacement costs and
reduce downtimeldquoOffering a complete line of prod-
ucts with comprehensive services will
be another feather in the cap of ven-
dors looking to widen their consumer
baserdquo notes Frost Industrial Automa-
tion and Process Control Research
Analyst Guru Mahesh
Moore says the trend of outsourcing
manufacturing to regions where labor
and production costs are favorable is
becoming less of a factor
ldquoThe days when cheap labor made
a significant difference in where a prod-
uct is manufactured mdash particularly high
value-added products or high weight
and bulk products mdash are coming to
an end as the cost of transportation
storage and inventory balance out the
benefits of production costs where la-
bor is a smaller percentage of the cost
of manufacturingrdquo Moore says ldquoLocal
manufacturing development will indeed
come to developing countries as their
ability to create markets that generate
economies of scale that support local
production is a clear trend and one that
all manufacturers will pay attention tordquo
Moore says that development of
maintenance-free or predictive tech-
nologies and products will be a sig-
nificant advantage to everyone in the
Bearing amp Coupling Manufacturers Focus
onDEVELOPING Economies
amp EFFICIENCY InnovationBy Amy W Richardson
2 January 2015
Flow Control Magazine
|
gy
Anew study from Frost amp Sullivan (wwwfrostcom) fore-
casts steady growth for the overall bearings and couplings
market based on rapid industrial development in high-growth
regions Specifically Frost predicts development in Mexico
Indonesia Nigeria Turkey Brazil Russia India and Chinawill help boost the bearings amp couplings market from $2206
billion in 2013 to an estimated $2676 billion in 2018
The development of maintenance-freeor predictive technologies will helpboost growth in the bearings market For example SKF is developing products that will automatically notifyusers when a bearing or mechanicalrotating component is approachingthe end of its useful life Pictured hereis an SKF Microlog analyzer a por- table condition monitoring tool
COURTESY SKF
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
improved productivity through simplified solutions The powerful technology and tools ensure repeatable
reliable accurate measurements Easier access to process data allows for better troubleshooting process
optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
For daily product notes visit the lsquoFeatured Productsrsquo section flowcontrolnetworkcom
ON THE WEB
1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
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FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
and benefits as well as grids of
instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
services provided for the
mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
Brought to you by Beamex
Your Source For Fluid Handling Videos
Go towwwflowcontrolnetworkcomfreeinfo
Select appropriate issue ofFlow Control Magazine
Select advertisements thatinterest you
Enter your email amp clickldquoSubmit Requestrdquo
1
2
3
4
PRODUCT
INFORMATION
ONLINE
Follow these 4 steps to receive freeproduct information from suppliers
FREE
FEATURED VIDEO How to Calibrate aPressure Measurement Loop
For more information about FlowTube
sponsor packs email FlowControlGrandViewMediacom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4245
THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
Name ________________________________________________________________
Title _________________________________________________________________
Company _____________________________________________________________
AddressCityStateZip __________________________________________________
______________________________________________________________________
Phone ________________________________________________________________
E-Mail ________________________________________________________________
One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545
![Page 27: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/27.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2745
The design and operation of compressors with side-
streams has always been difficult because flow entering the
compressor needs to be mixed with the core flow already
in the compressor (compressed in section-1) in a manner
that does not degrade the aerodynamic performance of sur-
rounding sections Minimizing losses and ensuring proper
mixing of the side-stream flow and core-flow are required to
ensure effective performance of a compressor of this sort
Key considerations for an application involving compres-
sors with side-stream flow include
The plant process typically dictates the side-stream
flange pressure
The impellers upstream of the side-stream should
achieve the necessary pressure for the core-flow
The side-stream flow is typically at a temperature dif-
ferent from compressor core-flow temperature
Process plants need some degree of operational flex-
ibility ie the ability to support variations in core-flow condi-
tions and side-stream conditions
Modern process plants are usually specifying more than
one operating conditions (sometimes two or more manda-
tory conditions) which can present challenges to compres-
sors with side-streams Adding to these issues modern
compressors should operate with much higher impeller tip
The COMPLICATED CASE ofCompressors with Side-StreamsConsidering key system design requirements
to ensure operational efficiency By Amin Almasi
4 January 2015
Flow Control Magazine
|
y
g
Some compressors in certain applications
have one or more incoming side-streams
(or side-loads) that introduce side-stream
flow to mix with the core flow In other words
a radial side-stream inlet is utilized in multi-
impeller centrifugal compressors to introduce
additional gas into the mid-stage of a com-
pressor This design enables optimization in
some process plants However the flow dis-
tribution after the junction of the side-stream
and the main return channel of the upstream
section can significantly affect the perfor-mance of the next section of compressor
In most cases the pressure levels at these
side-streams should be accurately predicted
to meet the theoretical performance
Compressor station at a natural gas processing plant
R U D M E R Z W E R V E R I S T O C K
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2845
speeds and inlet Mach numbers compared to previous
generations of compressor technology
Likewise side-streams are now com-
monly used with medium-sized and
large-sized compressors (eg 1ndash60
MW) The costs associated with cor-
rections on side-stream compres-
sor applicationsmdashany repair
inefficient operation and power
lossesmdashwould be very high Fur-
ther compressors with side-streams
are usually sensitive and difficult
machines to operate In particular
performance curves (performance
pressures efficiency etc) are sen-
sitive to suction inlet conditionsside-stream inlet conditions vol-
ume flow ratio (side-stream vol-
ume to core-flow volume) and side-stream losses
Compressors with side-stream often perform far below
expectations The main reason is that side-stream compres-
sors are different than conventional compressors (without
a side-stream) in design and operation For a compressor
with side-streams tighter tolerances in operating conditions
must be identified and applied Uncontrolled variations of
suction pressure or side-stream pressure are major prob-
lems Another major issue is the variations of the flow ratio
(side-stream flow to core-flow)
Compressor Side-Stream amp Mixing SectionIn many centrifugal compressors the portion of the side-
stream system from the flange connection to the mixing
section is similar to a compressor inlet A great challenge
is ensuring the mixing section provides circumferentially
uniform merged-flow with minimum losses This can be
achieved via effective design of the inlet configuration and
mixing section of the side-stream compressor such that
the impeller can be maintained over the whole operating
range of the compressor In many cases while there are
mixing sections provided for the machine the flows do not
completely mix before entering the impeller of the section-2
(the impeller after the mixing section) Non-uniformity at
inlet flow to the impeller is a key concern for compressor
performance
Another consideration is a compact design of the side-
stream mixing section Specifically a mixing section with
less axial length is always preferred This axial length can af-
fect the compressor rotor dynam-
ics the rotor length and over-
all compressor performance
(design cost operation and
reliability)
The side-stream exit pressure
(side-stream pressure at inlet
of the mixing section) is mainly
a function of the side-stream
flow velocity and the pres-
sure in the previous section of
the compressor Conversely the side-
stream flange pressure can depend on
side-stream flow velocity and section-1
exit conditions Therefore the side-stream
inlet flange volume flow is a function of theflange pressure compressibility (at that
pressure and temperature) and mass flow
Some engineers assume that the side-stream flange pres-
sure is equal to the inlet pressure of the first impeller of the
section-2 This is not true The mixed total pressure can be
estimated on a mass-averaged basis using side-stream total
pressure and return channel exit (section-1) total pressure
In some designs because of the lower static pressure at
the side-stream exit the total pressure at the return channel
exit is lower even though the velocity upstream is roughly
matched for both streams The pressure usually increased
at the returned channel but it can be reduced again at the
side-stream exit While simple in nature this can have an
impact on the prediction of pressure at the side-stream exit
and overall mixing section performance Based on basic flow
principles it was usually assumed that the static pressure
was equal between both flow streams at the mixing location
While this assumption might be used in rough calculations
the accurate simulations have shown this assumption is not
true In fact there are some points (for instance the shroud
wall at the exit of the return channel and the hub wall at
the exit of the side-stream) where this assumption is true
However this is not valid for all locations There are pressure
changes that occur from a side-stream flange to the inlet
of the next section (section-2) which depend on different
factors The first factor is the frictional losses due to side-
stream geometry from side-stream flange to plenum mix-
ing section etc The other factors are pressure changes due
to local curvature and geometry details of mixing section
Another consideration is the operation of a compressor
with side-stream at part-load The performance of the side-
wwwflowcontrolnetworkcom January 2015 25
Figure 1 An example of a centrifugalcompressor with side-stream
COURTESY SIEMENS
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 29456 January 2015
Flow Control Magazine
|
y
g
stream path the mixing section and
the downstream impellers when ma-
chine is operated at part-load or even
off-design operating flows will result
in additional compressor performance
problems In such a case both veloc-
ity profiles and pressure variations in
various parts (side-stream path mixing
section etc) will be different resulting
in complicated flow patterns and com-
plex aerodynamics behaviors
Side-Stream CompressorSectional Performance
Typically vendor-supplied compressor
performance curves reflect flange-to-flange performance because that is
what the plant engineers need to
evaluate the proper operation of their
system (for example from suction to
side-stream and from side-stream to
discharge) In many cases compres-
sor vendors also provide the over-
all compressor performance curves
and performance curves for section-1
(from suction to side-stream) and sec-
tion-2 (from side-stream to discharge)
Flange-to-flange data if not interpret-
ed properly can lead to false conclu-
sions about the relative performance
of individual sections of a compression
system For example if side-stream
losses from the flange to mixing sec-
tion are attributed to the downstream
section (section-2) it will cause the
downstream section (section-2) to
appear low in performance while the
upstream section (section-1) will show
high performance levels
An important behavior to con-
sider is when the actual side-stream
pressure is different than the rated
side-stream pressure When the side-
stream pressure is slightly higher than
the outlet pressure of the section-1
it (section-1) shows a relatively higher
performance compared to the real sec-
tion-1 performance In some cases
the performance of section-1 could be
considerably higher than section-2 In
other words when performance is de-
termined flange to flange the higher
flange pressure is seen as extra ldquopseu-
dordquo work done by the section (since this
is an inconsistent thermodynamic vol-
ume) resulting in a relatively high sec-
tional efficiency (section-1 shows a rel-
atively high efficiency) This is the case
for many compressors with side-stream
because the whole system is designed
(or specifically the side-stream location
is selected) in a way aimed at main-
taining the real side-stream pressure(side-stream inlet) above the section-1
outlet pressure because if the real side-
stream pressure becomes lower than
the section-1 outlet pressure the flow
may (theoretically) reverse
This is particularly important when
the side-stream mass flow is much
lower than the mass flow of core-flow
The above-mentioned reasons explain
why in many simulations calcula-
tions and performance reports related
to compressors with side-stream the
section-1 shows a relatively good ef-
ficiency and section-2 appears low in
efficiency
When the side-stream pressure is
slightly lower than the outlet pressure
of the section-1 the section-1 might
show a relatively lower performance
compared to section-2 This could oc-
cur in some recycle services where the
side-stream is actually a recycle flow
with a mass flow around two to five
times the core-flow The side-stream
(recycle) flow is returned from down-
stream of the compressor to be slightly
compressed and recycled to the down-
stream Such a recycled side-stream
compressor can present unique chal-
lenges for design and operation This
kind of machine usually needs very
special operating procedures and very
fine adjustments regarding operating
pressures and flows
Side-Stream Compressor
Performance amp Operation An important consideration is the sen-
sitivity of compressor overall perfor-
mance curve and sectional perfor-
mance curves to the flow ratio (ratio
of side-stream flow to core-flow) and
to the inlet conditions Variations in
the flow and pressure of the main
suction and side-stream inlet should
be controlled within tight tolerances
For compressors with side-stream the ASME PTC-10 code stipulates limits on
flow ratio (side-stream volume to core-
flow volume) The acceptable variation
in volume flow ratio in a compressor
with a side-stream is +-5 percent as
per ASME PTC code The requested
side-stream pressure tolerance is not
usually specified in compressor codes
but it should be around +- 2 percent
(or sometimes +- 25 percent)
Variance in flow ratio impacts the
velocity levels where the two streams
merge Significant variation in the ve-
locity profile upstream of the impeller
changes the incidence on the blade
leading edge of the following impel-
ler This change in incidence leads to a
change in sectional performance over-
all compressor performance and train
efficiency
If the flow ratio is varied between 95
percent and 105 percent (tolerances
specified in the ASME PTC-10 code)
the flange pressure changes accord-
ingly resulting in a change in the sec-
tional performance and overall perfor-
mance The sectional efficiency varies
sometimes more than +- 4 percent
This variance reduces as the flow is de-
creased toward surge However as the
flow is increased toward overload the
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3045wwwflowcontrolnetworkcom January 2015 27
variance increases up to higher values
(even in some cases three to five times
compared to variations near the surge
zone) For example in a case study
for a compressor with side-streams a
+- 5 percent variation in flow ratio and
associated changes (pressures losses
etc) the sectional efficiency reduced by
approximately 34 percent at the rated
flow at allowable operating points at
the end of curve (near the overload
ie choke) efficiency reduced by ap-
proximately 55 percent These results
show that the variation in sectional
performance and overall performance
due to flow ratio is highest at operat-ing points near the overload and low-
est at operating points near the surge
For compressors which work most of
the time at high flow (flow higher than
rated flow and discharge pressure low-
er than rated pressure) the effects of
flow ratio deviations (and subsequently
efficiency reduction) would be higher
than compressors working on the left-
hand side of curve (say with sufficient
margins near the surge)
In the compressor codes (such as
API 617) the compressor power varia-
tions should be maintained below 4
percent However in some applica-
tions clients require tighter tolerances
on the consumed power sometimes
below 2 percent (or even below 15
percent) Some studies suggest while
+- 5 percent of volume flow ratio is
suitable for performance test as per
ASME PTC-10 code some plants re-
quire tighter control on the consumed
power and compressor performance
(lower limits on the efficiency) the tol-
erances on the volume flow ratio could
be tighter than ASME PTC code In this
regard +- 4 percent tolerance can be
suggested on the volume flow ratio (ra-
tio of side-stream flow to core-flow) of
compressors with side-streams
Based on operational experiences
acceptable variations in volume flow
ratio and inlet pressures (suction inlet
and side-stream inlet) of a compressor
with side-streams are +- 4 percent
and +- 2 percent respectively
Another important consideration is
the required adjustments for the flow
ratio (side-stream flow to core-flow)
Compressors with side-stream usually
require fixed side-stream flange pres-
sures For a compressor with some variations in operation conditions (even
small changes) it is not usually pos-
sible to achieve optimum operation by
keeping the flow ratio (side-stream to
core-flow) constant The flow ratio has
to be adjusted according to the inlet
flow at which the machine is operating
in order to get the required correspond-
ing side-stream flange pressure
Thermal changes have also been
known to cause some instability in
centrifugal compressors An example is
the thermal-induced change of resid-
ual unbalance For compressors with
side-streams which feature tempera-
ture differences between core-flow and
side-stream flow the thermal behav-
ior of the compressor is usually more
complex and requires more attention
Heavy Gas ChallengeHeavy gases (such as heavy hydrocar-
bon gases eg propane propylene
MTBE (Methyl Tertiary Butyl Ether))
have very low gas sonic velocities that
produce high Mach numbers in the
aerodynamic flow paths For these
services because of high Mach num-
ber high flow coefficient stages have
very narrow flow maps characterized
by limited surge and choke margins
Compressors with side-streams in
these services present great challeng-
es This is to say the side-streams and
associated mixing further complicate
design operation and performance
prediction because the pressure tem-
perature and flow conditions at each
one of these side-streams as well
as at the exit of the machine require
stringent tolerances to optimize the
overall efficiency and performance
As such it is important to accuratelymodel design operate and moni-
tor performance characteristics of any
impellers diffusers return channels
and generally all flow-path components
in a compressor with side-stream FC
Amin Almasi
is a senior rotating
machine consultant
in Australia He is
a chartered profes- sional engineer of
Engineers Australia
(MIEAust CPEng ndash
Mechanical) and
IMechE (CEng MIMechE) holds
bachelorrsquos and masterrsquos degrees
in Mechanical Engineering and is
a registered professional engineer
in Queensland He specializes in
rotating machines including cen-
trifugal screw and reciprocating
compressors gas turbines steamturbines engines pumps subsea
offshore rotating machines LNG
units condition monitoring and reli-
ability Mr Almasi is an active mem-
ber of Engineers Australia IMechE
ASME and SPE He can be reached
at aminalmasiymailcom
Amin Almasi
Compressor | Gas Flow | Performance Curve | Side-Stream Flow
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3145
The pressure in the stuffing box
containing the packing can be estimat-
ed by the following equation
SBP = [Discharge ndash Suction] 3 + Suction
Pressure at the bottom of the stuff-
ing box will be higher than the suction
pressure but considerably lower than
the discharge pressure It should be
noted this calculation will yield a con-
servative estimate of stuffing box pres-
sure that can be further reduced by
pump design
A hole in the stuffing box serves as
a port for injecting clean fluid that cir-
culates around a lantern ring aligned
under the flush port The fluid flushes
solids back into the process to protect
the packing from abrasive wear If the
clean fluid is injected at a pressure ex-
ceeding that at the bottom of the stuff-
ing box some of it will leak back into
the process and some will leak out to
the atmosphere Recommended flush
injection pressure is 15ndash30 PSI (1ndash2
Bar) greater than the pressure at the
bottom of the stuffing box
Fluid injection is also used to lubri-
cate and cool dry-running packing that
is subject to frictional heat and to pre-
vent air from entering the pump which
reduces flow and operating efficiency
Centrifugal pumps utilize three
types of impellersmdashopen semi-open
and closed (Figures 2 3 amp 4) Open
designs prevent fluids with large solids
from clogging the impellers but at theexpense of pump efficiency Backing
plates on semi-open designs serve to
trap the fluid for more efficient opera-
tion Closed impellers are for use with
clean fluids since solids could ac-
cumulate in the eye which would re-
quire tearing down the pump to remove
them
Single-Stage CentrifugalPumpsSingle-stage centrifugal pumps typi-
cally have good bearing support of the
shaft with few run-out or ldquowhiprdquo prob-
lems However in some cases they
are subject to cavitation This occurs
in the eye of the impeller where the
fluid is under vacuum If the pressure
is low enough it will cause the material
to vaporize forming air or water vapor
bubbles As the fluid passes through
How Pumping Systems Design Affects Sealing Performance
By Chris Boss
8 January 2015
Flow Control Magazine
|
Understanding how different types of pump designs impact
sealing is critical to optimizing efficiency safety and lon-
gevity of the sealing system Used for a wide variety of media
including clear fluids solutions and slurries single-stage
centrifugal pumps are one of the most common
types (Figure 1) Fluid drawn into these pumps
enters the eye of an impeller that spins itto the outside of its container
or volute building pressure as
it moves toward discharge
Some of this fluid will work
its way behind the impeller
where it must be sealed with
compression packing or a
mechanical seal
Figure 1
Figure 2 Figure 3 Figure 4
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3245
the pump under increasing pressure
these bubbles implode sending shock
and vibration through the impeller
adversely affecting the seal This phe-
nomenon can be mitigated by running
the pump at slower speed and higher
pressure at the suction end to prevent
air from entering the fluid
Double-Ended Split-CasePumpsOperating on the same centrifugal prin-
ciple but slightly different geometry are
double-ended split-case pumps (Figure
5) Fluid enters both ends of the pump
and is directed into the eye of an impel-ler which spins it out of the volute to
discharge Packing is installed on both
the shaft and bearing ends so the stuff-
ing box is exposed only to suction pres-
sure which is usually quite low
Axial Flow Pumps Axial flow pumps operate like hydro
turbines in reverse whereby a propeller
(or axial impeller) pushes the fluid to
discharge (Figure 6)
Since the stuffing box is located
downstream of the propeller at the dis-
charge end of the pump the packing is
exposed to the full discharge pressure
Vertical PumpsVertical turbine pumps are typically
flange-mounted on a floor extending
downward into a water-filled sump
hole (Figure 7) Available as single- or
multi-stage pumps they feature an
impeller or series of impellers rotated
simultaneously by a single shaft The
impellers increase the pressure of the
upward flow subjecting the stuffing box
to full discharge pressure
Vertical pumps can be quite long so
inadequate bearing support can cause
the shaft to run out This can induce
undesirable lateral motion on the pack-
ing Worse the packing may be forced
to serve both as a bearing and a seal To
withstand these conditions the packing
should be resilient elastic and resistant
to deformation These properties rule
out packing such as graphite foil in favor
of fiber-based materials
Multi-Stage PumpsMulti-stage pumps are used for high-
pressure applications such as feeding
the boilers in steam-powered generating
plants Stuffing box pressure can vary
with pump design and number of stag-
es Designed for clean fluids and high
operating speeds these pumps typically
have high- and low-pressure ends with ahydraulic pressure equalization line run-
ning between the stuffing boxes
Like vertical pumps multi-stage
pumps feature a series of impellers to
build fluid discharge pressure In the
case of the six-stage pump pictured in
Figure 8 fluid enters at the drive end
where a stuffing box is exposed to suc-
tion pressure Channeled from one
impeller to the next through the pump
casting the fluid can reach extremely
high pressures at discharge
A second stuffing box located at the
bearing end is exposed to an intermedi-
ate pressure from the third impeller This
pressure is greater than the suction pres-
sure but much less than the discharge
pressure which can reach 2000 PSI
Fortunately the stuffing boxes in
these pumps are not exposed to dis-
charge pressures and typically see be-
low 500 PSI which is within the range
of some packing materials
wwwflowcontrolnetworkcom January 2015 29
Figure 5
Figure 6
Figure 7
Figure 8
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 33450 January 2015
Flow Control Magazine
| Gear PumpsPositive-displacement or gear pumps
operate on a different principle than
centrifugal pumps In external gear
pumps the fluid flows around the out-
side of the gears the intermeshing
of which forces it through the pump
to discharge (Figure 9) This design
makes these pumps particularly suit-
able for use with highly viscous fluids
such as resins emulsions syrups and
adhesives As such they are used for
transfer or metering applications
It should be noted gear pumps will
continue to displace fluid as long as
their shafts are turning which can pose
a problem if a clog occurs at the dis-
charge The resulting buildup of pres-
sure can blow out seals and damage
the pump Therefore most gear pumps
have pressure relief valves to divert
fluid back to the suction side for re-
circulation through the pump Internal
gear pumps operate slightly differently
but also have pressure relief valves to
prevent damage from excessive pres-
sure (Figure 10) In both external and
internal gear pumps the maximum
stuffing box pressure is determined by
these valves
Other rotating equipment includes
mixersagitators which are similar to
pumps in terms of the speeds to which
the packing is exposed There are ba-
sically three types of mixersagitators
top- bottom- and side-entry Top-entry
models are subject to the same con-
cerns about shaft run-out ldquowhiprdquo and
lateral forces on the paddles that are
encountered in some vertical pumps
Although some fluid may splash onto
the packing these mixers basically run
dry so the packing must have the abil-
ity to dissipate the resulting frictional
heat
In bottom-entry mixers the packing
is always exposed to fluid and may also
be exposed to solids requiring abra-
sion-resistance If the seal fails the en-
tire contents of the tank will eventually
drain out onto the bearings the floor
and other components under the stuff-
ing box
The packing in side-entry mixers may
be fully or intermittently exposed to flu-
id as well as side loading and vibration
Aside from media temperature
speed and other application variables
the configurations and operating prin-
ciples of rotary-type pumps exert differ-
ent forces on the seals used to keep
them from leaking These forces can
spell the difference between accept-
able seal performance and failure
Understanding these differences has
important implications that should be
taken into account to assure proper
sealing selection for long-term trou-
ble-free performance FC
wwwgarlockcom
Chris Boss is
a senior applica-
tions engineer for
Garlock Sealing
Technologies in
Palmyra NY He
has held various
positions in produc-
tion engineering
product development and applica-
tions engineering for the companyrsquos
compression packing division He
is a BSME graduate of the State
University of New York at Buffalo Mr
Boss can be reached at 800 448-
6688 or chrisbossgarlockcom
Chris Boss
Cavitation | Centrifugal Pump | Pump Packing | Sealing System
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Figure 9
Figure 10
Aside from media temperature speed and
other application variables the configurations
and operating principles of rotary-type
pumps exert different forces on the seals used
to keep them from leaking These forces can
spell the difference between acceptable seal
performance and failure
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3445
NS IDERNDUSTRIAL AUTOMATION + PROCESS CONTROL
WANT
INFORMATION
ON THE
automationindustry
SUBSCRIBE NOW at wwwiainsidercouk
Published by Spitzer and Boyes LLC Write in 15 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3545
Frost says the push from developing
economies is important as the market
is technologically mature and seeing
restricted growth in developed econo-
mies This is particularly true in Europe
and North America where recent finan-
cial insta-
bility has
reduced capital expenditure across end-
user industries
Bill Moore senior vice president of
sales development and channel man-
agement for global bearings manufac-
turer SKF says ldquosmartrdquo products and
the expansion of robust reliability pro-
grams are helping to drive new invest-
ment particularly in developed coun-
tries where the cost to compete is
high Frost says the magnitude of
the existing global installed base will
strengthen the need for replacement
and upgrades adding to market de-
mand as well
Frost says despite the potential
in developing economies the focus
on price as a product differentiator
may lead to intense price pressures
among manufacturers and bring down
the value of the overall market in the
short term The growing trend among
consumers to choose low-cost Chinese
imports will complicate this challenge
As price and quality become stan-
dardized across the globe customers
will base more of their purchasing deci-
sions on value-added services accord-
ing to Frost This will push manufactur-
ers to create more maintenance-free
solutions such as lubrication-free
bearings that offer end-users savings
on service and replacement costs and
reduce downtimeldquoOffering a complete line of prod-
ucts with comprehensive services will
be another feather in the cap of ven-
dors looking to widen their consumer
baserdquo notes Frost Industrial Automa-
tion and Process Control Research
Analyst Guru Mahesh
Moore says the trend of outsourcing
manufacturing to regions where labor
and production costs are favorable is
becoming less of a factor
ldquoThe days when cheap labor made
a significant difference in where a prod-
uct is manufactured mdash particularly high
value-added products or high weight
and bulk products mdash are coming to
an end as the cost of transportation
storage and inventory balance out the
benefits of production costs where la-
bor is a smaller percentage of the cost
of manufacturingrdquo Moore says ldquoLocal
manufacturing development will indeed
come to developing countries as their
ability to create markets that generate
economies of scale that support local
production is a clear trend and one that
all manufacturers will pay attention tordquo
Moore says that development of
maintenance-free or predictive tech-
nologies and products will be a sig-
nificant advantage to everyone in the
Bearing amp Coupling Manufacturers Focus
onDEVELOPING Economies
amp EFFICIENCY InnovationBy Amy W Richardson
2 January 2015
Flow Control Magazine
|
gy
Anew study from Frost amp Sullivan (wwwfrostcom) fore-
casts steady growth for the overall bearings and couplings
market based on rapid industrial development in high-growth
regions Specifically Frost predicts development in Mexico
Indonesia Nigeria Turkey Brazil Russia India and Chinawill help boost the bearings amp couplings market from $2206
billion in 2013 to an estimated $2676 billion in 2018
The development of maintenance-freeor predictive technologies will helpboost growth in the bearings market For example SKF is developing products that will automatically notifyusers when a bearing or mechanicalrotating component is approachingthe end of its useful life Pictured hereis an SKF Microlog analyzer a por- table condition monitoring tool
COURTESY SKF
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
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use and support FREE INFO WRITE IN 100 |
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2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3845
FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
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eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
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mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
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market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
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CD The CD offers interactive
features including keyword
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print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
Brought to you by Beamex
Your Source For Fluid Handling Videos
Go towwwflowcontrolnetworkcomfreeinfo
Select appropriate issue ofFlow Control Magazine
Select advertisements thatinterest you
Enter your email amp clickldquoSubmit Requestrdquo
1
2
3
4
PRODUCT
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ONLINE
Follow these 4 steps to receive freeproduct information from suppliers
FREE
FEATURED VIDEO How to Calibrate aPressure Measurement Loop
For more information about FlowTube
sponsor packs email FlowControlGrandViewMediacom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4245
THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
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Title _________________________________________________________________
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AddressCityStateZip __________________________________________________
______________________________________________________________________
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One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545
![Page 28: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/28.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 2845
speeds and inlet Mach numbers compared to previous
generations of compressor technology
Likewise side-streams are now com-
monly used with medium-sized and
large-sized compressors (eg 1ndash60
MW) The costs associated with cor-
rections on side-stream compres-
sor applicationsmdashany repair
inefficient operation and power
lossesmdashwould be very high Fur-
ther compressors with side-streams
are usually sensitive and difficult
machines to operate In particular
performance curves (performance
pressures efficiency etc) are sen-
sitive to suction inlet conditionsside-stream inlet conditions vol-
ume flow ratio (side-stream vol-
ume to core-flow volume) and side-stream losses
Compressors with side-stream often perform far below
expectations The main reason is that side-stream compres-
sors are different than conventional compressors (without
a side-stream) in design and operation For a compressor
with side-streams tighter tolerances in operating conditions
must be identified and applied Uncontrolled variations of
suction pressure or side-stream pressure are major prob-
lems Another major issue is the variations of the flow ratio
(side-stream flow to core-flow)
Compressor Side-Stream amp Mixing SectionIn many centrifugal compressors the portion of the side-
stream system from the flange connection to the mixing
section is similar to a compressor inlet A great challenge
is ensuring the mixing section provides circumferentially
uniform merged-flow with minimum losses This can be
achieved via effective design of the inlet configuration and
mixing section of the side-stream compressor such that
the impeller can be maintained over the whole operating
range of the compressor In many cases while there are
mixing sections provided for the machine the flows do not
completely mix before entering the impeller of the section-2
(the impeller after the mixing section) Non-uniformity at
inlet flow to the impeller is a key concern for compressor
performance
Another consideration is a compact design of the side-
stream mixing section Specifically a mixing section with
less axial length is always preferred This axial length can af-
fect the compressor rotor dynam-
ics the rotor length and over-
all compressor performance
(design cost operation and
reliability)
The side-stream exit pressure
(side-stream pressure at inlet
of the mixing section) is mainly
a function of the side-stream
flow velocity and the pres-
sure in the previous section of
the compressor Conversely the side-
stream flange pressure can depend on
side-stream flow velocity and section-1
exit conditions Therefore the side-stream
inlet flange volume flow is a function of theflange pressure compressibility (at that
pressure and temperature) and mass flow
Some engineers assume that the side-stream flange pres-
sure is equal to the inlet pressure of the first impeller of the
section-2 This is not true The mixed total pressure can be
estimated on a mass-averaged basis using side-stream total
pressure and return channel exit (section-1) total pressure
In some designs because of the lower static pressure at
the side-stream exit the total pressure at the return channel
exit is lower even though the velocity upstream is roughly
matched for both streams The pressure usually increased
at the returned channel but it can be reduced again at the
side-stream exit While simple in nature this can have an
impact on the prediction of pressure at the side-stream exit
and overall mixing section performance Based on basic flow
principles it was usually assumed that the static pressure
was equal between both flow streams at the mixing location
While this assumption might be used in rough calculations
the accurate simulations have shown this assumption is not
true In fact there are some points (for instance the shroud
wall at the exit of the return channel and the hub wall at
the exit of the side-stream) where this assumption is true
However this is not valid for all locations There are pressure
changes that occur from a side-stream flange to the inlet
of the next section (section-2) which depend on different
factors The first factor is the frictional losses due to side-
stream geometry from side-stream flange to plenum mix-
ing section etc The other factors are pressure changes due
to local curvature and geometry details of mixing section
Another consideration is the operation of a compressor
with side-stream at part-load The performance of the side-
wwwflowcontrolnetworkcom January 2015 25
Figure 1 An example of a centrifugalcompressor with side-stream
COURTESY SIEMENS
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 29456 January 2015
Flow Control Magazine
|
y
g
stream path the mixing section and
the downstream impellers when ma-
chine is operated at part-load or even
off-design operating flows will result
in additional compressor performance
problems In such a case both veloc-
ity profiles and pressure variations in
various parts (side-stream path mixing
section etc) will be different resulting
in complicated flow patterns and com-
plex aerodynamics behaviors
Side-Stream CompressorSectional Performance
Typically vendor-supplied compressor
performance curves reflect flange-to-flange performance because that is
what the plant engineers need to
evaluate the proper operation of their
system (for example from suction to
side-stream and from side-stream to
discharge) In many cases compres-
sor vendors also provide the over-
all compressor performance curves
and performance curves for section-1
(from suction to side-stream) and sec-
tion-2 (from side-stream to discharge)
Flange-to-flange data if not interpret-
ed properly can lead to false conclu-
sions about the relative performance
of individual sections of a compression
system For example if side-stream
losses from the flange to mixing sec-
tion are attributed to the downstream
section (section-2) it will cause the
downstream section (section-2) to
appear low in performance while the
upstream section (section-1) will show
high performance levels
An important behavior to con-
sider is when the actual side-stream
pressure is different than the rated
side-stream pressure When the side-
stream pressure is slightly higher than
the outlet pressure of the section-1
it (section-1) shows a relatively higher
performance compared to the real sec-
tion-1 performance In some cases
the performance of section-1 could be
considerably higher than section-2 In
other words when performance is de-
termined flange to flange the higher
flange pressure is seen as extra ldquopseu-
dordquo work done by the section (since this
is an inconsistent thermodynamic vol-
ume) resulting in a relatively high sec-
tional efficiency (section-1 shows a rel-
atively high efficiency) This is the case
for many compressors with side-stream
because the whole system is designed
(or specifically the side-stream location
is selected) in a way aimed at main-
taining the real side-stream pressure(side-stream inlet) above the section-1
outlet pressure because if the real side-
stream pressure becomes lower than
the section-1 outlet pressure the flow
may (theoretically) reverse
This is particularly important when
the side-stream mass flow is much
lower than the mass flow of core-flow
The above-mentioned reasons explain
why in many simulations calcula-
tions and performance reports related
to compressors with side-stream the
section-1 shows a relatively good ef-
ficiency and section-2 appears low in
efficiency
When the side-stream pressure is
slightly lower than the outlet pressure
of the section-1 the section-1 might
show a relatively lower performance
compared to section-2 This could oc-
cur in some recycle services where the
side-stream is actually a recycle flow
with a mass flow around two to five
times the core-flow The side-stream
(recycle) flow is returned from down-
stream of the compressor to be slightly
compressed and recycled to the down-
stream Such a recycled side-stream
compressor can present unique chal-
lenges for design and operation This
kind of machine usually needs very
special operating procedures and very
fine adjustments regarding operating
pressures and flows
Side-Stream Compressor
Performance amp Operation An important consideration is the sen-
sitivity of compressor overall perfor-
mance curve and sectional perfor-
mance curves to the flow ratio (ratio
of side-stream flow to core-flow) and
to the inlet conditions Variations in
the flow and pressure of the main
suction and side-stream inlet should
be controlled within tight tolerances
For compressors with side-stream the ASME PTC-10 code stipulates limits on
flow ratio (side-stream volume to core-
flow volume) The acceptable variation
in volume flow ratio in a compressor
with a side-stream is +-5 percent as
per ASME PTC code The requested
side-stream pressure tolerance is not
usually specified in compressor codes
but it should be around +- 2 percent
(or sometimes +- 25 percent)
Variance in flow ratio impacts the
velocity levels where the two streams
merge Significant variation in the ve-
locity profile upstream of the impeller
changes the incidence on the blade
leading edge of the following impel-
ler This change in incidence leads to a
change in sectional performance over-
all compressor performance and train
efficiency
If the flow ratio is varied between 95
percent and 105 percent (tolerances
specified in the ASME PTC-10 code)
the flange pressure changes accord-
ingly resulting in a change in the sec-
tional performance and overall perfor-
mance The sectional efficiency varies
sometimes more than +- 4 percent
This variance reduces as the flow is de-
creased toward surge However as the
flow is increased toward overload the
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3045wwwflowcontrolnetworkcom January 2015 27
variance increases up to higher values
(even in some cases three to five times
compared to variations near the surge
zone) For example in a case study
for a compressor with side-streams a
+- 5 percent variation in flow ratio and
associated changes (pressures losses
etc) the sectional efficiency reduced by
approximately 34 percent at the rated
flow at allowable operating points at
the end of curve (near the overload
ie choke) efficiency reduced by ap-
proximately 55 percent These results
show that the variation in sectional
performance and overall performance
due to flow ratio is highest at operat-ing points near the overload and low-
est at operating points near the surge
For compressors which work most of
the time at high flow (flow higher than
rated flow and discharge pressure low-
er than rated pressure) the effects of
flow ratio deviations (and subsequently
efficiency reduction) would be higher
than compressors working on the left-
hand side of curve (say with sufficient
margins near the surge)
In the compressor codes (such as
API 617) the compressor power varia-
tions should be maintained below 4
percent However in some applica-
tions clients require tighter tolerances
on the consumed power sometimes
below 2 percent (or even below 15
percent) Some studies suggest while
+- 5 percent of volume flow ratio is
suitable for performance test as per
ASME PTC-10 code some plants re-
quire tighter control on the consumed
power and compressor performance
(lower limits on the efficiency) the tol-
erances on the volume flow ratio could
be tighter than ASME PTC code In this
regard +- 4 percent tolerance can be
suggested on the volume flow ratio (ra-
tio of side-stream flow to core-flow) of
compressors with side-streams
Based on operational experiences
acceptable variations in volume flow
ratio and inlet pressures (suction inlet
and side-stream inlet) of a compressor
with side-streams are +- 4 percent
and +- 2 percent respectively
Another important consideration is
the required adjustments for the flow
ratio (side-stream flow to core-flow)
Compressors with side-stream usually
require fixed side-stream flange pres-
sures For a compressor with some variations in operation conditions (even
small changes) it is not usually pos-
sible to achieve optimum operation by
keeping the flow ratio (side-stream to
core-flow) constant The flow ratio has
to be adjusted according to the inlet
flow at which the machine is operating
in order to get the required correspond-
ing side-stream flange pressure
Thermal changes have also been
known to cause some instability in
centrifugal compressors An example is
the thermal-induced change of resid-
ual unbalance For compressors with
side-streams which feature tempera-
ture differences between core-flow and
side-stream flow the thermal behav-
ior of the compressor is usually more
complex and requires more attention
Heavy Gas ChallengeHeavy gases (such as heavy hydrocar-
bon gases eg propane propylene
MTBE (Methyl Tertiary Butyl Ether))
have very low gas sonic velocities that
produce high Mach numbers in the
aerodynamic flow paths For these
services because of high Mach num-
ber high flow coefficient stages have
very narrow flow maps characterized
by limited surge and choke margins
Compressors with side-streams in
these services present great challeng-
es This is to say the side-streams and
associated mixing further complicate
design operation and performance
prediction because the pressure tem-
perature and flow conditions at each
one of these side-streams as well
as at the exit of the machine require
stringent tolerances to optimize the
overall efficiency and performance
As such it is important to accuratelymodel design operate and moni-
tor performance characteristics of any
impellers diffusers return channels
and generally all flow-path components
in a compressor with side-stream FC
Amin Almasi
is a senior rotating
machine consultant
in Australia He is
a chartered profes- sional engineer of
Engineers Australia
(MIEAust CPEng ndash
Mechanical) and
IMechE (CEng MIMechE) holds
bachelorrsquos and masterrsquos degrees
in Mechanical Engineering and is
a registered professional engineer
in Queensland He specializes in
rotating machines including cen-
trifugal screw and reciprocating
compressors gas turbines steamturbines engines pumps subsea
offshore rotating machines LNG
units condition monitoring and reli-
ability Mr Almasi is an active mem-
ber of Engineers Australia IMechE
ASME and SPE He can be reached
at aminalmasiymailcom
Amin Almasi
Compressor | Gas Flow | Performance Curve | Side-Stream Flow
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3145
The pressure in the stuffing box
containing the packing can be estimat-
ed by the following equation
SBP = [Discharge ndash Suction] 3 + Suction
Pressure at the bottom of the stuff-
ing box will be higher than the suction
pressure but considerably lower than
the discharge pressure It should be
noted this calculation will yield a con-
servative estimate of stuffing box pres-
sure that can be further reduced by
pump design
A hole in the stuffing box serves as
a port for injecting clean fluid that cir-
culates around a lantern ring aligned
under the flush port The fluid flushes
solids back into the process to protect
the packing from abrasive wear If the
clean fluid is injected at a pressure ex-
ceeding that at the bottom of the stuff-
ing box some of it will leak back into
the process and some will leak out to
the atmosphere Recommended flush
injection pressure is 15ndash30 PSI (1ndash2
Bar) greater than the pressure at the
bottom of the stuffing box
Fluid injection is also used to lubri-
cate and cool dry-running packing that
is subject to frictional heat and to pre-
vent air from entering the pump which
reduces flow and operating efficiency
Centrifugal pumps utilize three
types of impellersmdashopen semi-open
and closed (Figures 2 3 amp 4) Open
designs prevent fluids with large solids
from clogging the impellers but at theexpense of pump efficiency Backing
plates on semi-open designs serve to
trap the fluid for more efficient opera-
tion Closed impellers are for use with
clean fluids since solids could ac-
cumulate in the eye which would re-
quire tearing down the pump to remove
them
Single-Stage CentrifugalPumpsSingle-stage centrifugal pumps typi-
cally have good bearing support of the
shaft with few run-out or ldquowhiprdquo prob-
lems However in some cases they
are subject to cavitation This occurs
in the eye of the impeller where the
fluid is under vacuum If the pressure
is low enough it will cause the material
to vaporize forming air or water vapor
bubbles As the fluid passes through
How Pumping Systems Design Affects Sealing Performance
By Chris Boss
8 January 2015
Flow Control Magazine
|
Understanding how different types of pump designs impact
sealing is critical to optimizing efficiency safety and lon-
gevity of the sealing system Used for a wide variety of media
including clear fluids solutions and slurries single-stage
centrifugal pumps are one of the most common
types (Figure 1) Fluid drawn into these pumps
enters the eye of an impeller that spins itto the outside of its container
or volute building pressure as
it moves toward discharge
Some of this fluid will work
its way behind the impeller
where it must be sealed with
compression packing or a
mechanical seal
Figure 1
Figure 2 Figure 3 Figure 4
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3245
the pump under increasing pressure
these bubbles implode sending shock
and vibration through the impeller
adversely affecting the seal This phe-
nomenon can be mitigated by running
the pump at slower speed and higher
pressure at the suction end to prevent
air from entering the fluid
Double-Ended Split-CasePumpsOperating on the same centrifugal prin-
ciple but slightly different geometry are
double-ended split-case pumps (Figure
5) Fluid enters both ends of the pump
and is directed into the eye of an impel-ler which spins it out of the volute to
discharge Packing is installed on both
the shaft and bearing ends so the stuff-
ing box is exposed only to suction pres-
sure which is usually quite low
Axial Flow Pumps Axial flow pumps operate like hydro
turbines in reverse whereby a propeller
(or axial impeller) pushes the fluid to
discharge (Figure 6)
Since the stuffing box is located
downstream of the propeller at the dis-
charge end of the pump the packing is
exposed to the full discharge pressure
Vertical PumpsVertical turbine pumps are typically
flange-mounted on a floor extending
downward into a water-filled sump
hole (Figure 7) Available as single- or
multi-stage pumps they feature an
impeller or series of impellers rotated
simultaneously by a single shaft The
impellers increase the pressure of the
upward flow subjecting the stuffing box
to full discharge pressure
Vertical pumps can be quite long so
inadequate bearing support can cause
the shaft to run out This can induce
undesirable lateral motion on the pack-
ing Worse the packing may be forced
to serve both as a bearing and a seal To
withstand these conditions the packing
should be resilient elastic and resistant
to deformation These properties rule
out packing such as graphite foil in favor
of fiber-based materials
Multi-Stage PumpsMulti-stage pumps are used for high-
pressure applications such as feeding
the boilers in steam-powered generating
plants Stuffing box pressure can vary
with pump design and number of stag-
es Designed for clean fluids and high
operating speeds these pumps typically
have high- and low-pressure ends with ahydraulic pressure equalization line run-
ning between the stuffing boxes
Like vertical pumps multi-stage
pumps feature a series of impellers to
build fluid discharge pressure In the
case of the six-stage pump pictured in
Figure 8 fluid enters at the drive end
where a stuffing box is exposed to suc-
tion pressure Channeled from one
impeller to the next through the pump
casting the fluid can reach extremely
high pressures at discharge
A second stuffing box located at the
bearing end is exposed to an intermedi-
ate pressure from the third impeller This
pressure is greater than the suction pres-
sure but much less than the discharge
pressure which can reach 2000 PSI
Fortunately the stuffing boxes in
these pumps are not exposed to dis-
charge pressures and typically see be-
low 500 PSI which is within the range
of some packing materials
wwwflowcontrolnetworkcom January 2015 29
Figure 5
Figure 6
Figure 7
Figure 8
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 33450 January 2015
Flow Control Magazine
| Gear PumpsPositive-displacement or gear pumps
operate on a different principle than
centrifugal pumps In external gear
pumps the fluid flows around the out-
side of the gears the intermeshing
of which forces it through the pump
to discharge (Figure 9) This design
makes these pumps particularly suit-
able for use with highly viscous fluids
such as resins emulsions syrups and
adhesives As such they are used for
transfer or metering applications
It should be noted gear pumps will
continue to displace fluid as long as
their shafts are turning which can pose
a problem if a clog occurs at the dis-
charge The resulting buildup of pres-
sure can blow out seals and damage
the pump Therefore most gear pumps
have pressure relief valves to divert
fluid back to the suction side for re-
circulation through the pump Internal
gear pumps operate slightly differently
but also have pressure relief valves to
prevent damage from excessive pres-
sure (Figure 10) In both external and
internal gear pumps the maximum
stuffing box pressure is determined by
these valves
Other rotating equipment includes
mixersagitators which are similar to
pumps in terms of the speeds to which
the packing is exposed There are ba-
sically three types of mixersagitators
top- bottom- and side-entry Top-entry
models are subject to the same con-
cerns about shaft run-out ldquowhiprdquo and
lateral forces on the paddles that are
encountered in some vertical pumps
Although some fluid may splash onto
the packing these mixers basically run
dry so the packing must have the abil-
ity to dissipate the resulting frictional
heat
In bottom-entry mixers the packing
is always exposed to fluid and may also
be exposed to solids requiring abra-
sion-resistance If the seal fails the en-
tire contents of the tank will eventually
drain out onto the bearings the floor
and other components under the stuff-
ing box
The packing in side-entry mixers may
be fully or intermittently exposed to flu-
id as well as side loading and vibration
Aside from media temperature
speed and other application variables
the configurations and operating prin-
ciples of rotary-type pumps exert differ-
ent forces on the seals used to keep
them from leaking These forces can
spell the difference between accept-
able seal performance and failure
Understanding these differences has
important implications that should be
taken into account to assure proper
sealing selection for long-term trou-
ble-free performance FC
wwwgarlockcom
Chris Boss is
a senior applica-
tions engineer for
Garlock Sealing
Technologies in
Palmyra NY He
has held various
positions in produc-
tion engineering
product development and applica-
tions engineering for the companyrsquos
compression packing division He
is a BSME graduate of the State
University of New York at Buffalo Mr
Boss can be reached at 800 448-
6688 or chrisbossgarlockcom
Chris Boss
Cavitation | Centrifugal Pump | Pump Packing | Sealing System
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Figure 9
Figure 10
Aside from media temperature speed and
other application variables the configurations
and operating principles of rotary-type
pumps exert different forces on the seals used
to keep them from leaking These forces can
spell the difference between acceptable seal
performance and failure
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3445
NS IDERNDUSTRIAL AUTOMATION + PROCESS CONTROL
WANT
INFORMATION
ON THE
automationindustry
SUBSCRIBE NOW at wwwiainsidercouk
Published by Spitzer and Boyes LLC Write in 15 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3545
Frost says the push from developing
economies is important as the market
is technologically mature and seeing
restricted growth in developed econo-
mies This is particularly true in Europe
and North America where recent finan-
cial insta-
bility has
reduced capital expenditure across end-
user industries
Bill Moore senior vice president of
sales development and channel man-
agement for global bearings manufac-
turer SKF says ldquosmartrdquo products and
the expansion of robust reliability pro-
grams are helping to drive new invest-
ment particularly in developed coun-
tries where the cost to compete is
high Frost says the magnitude of
the existing global installed base will
strengthen the need for replacement
and upgrades adding to market de-
mand as well
Frost says despite the potential
in developing economies the focus
on price as a product differentiator
may lead to intense price pressures
among manufacturers and bring down
the value of the overall market in the
short term The growing trend among
consumers to choose low-cost Chinese
imports will complicate this challenge
As price and quality become stan-
dardized across the globe customers
will base more of their purchasing deci-
sions on value-added services accord-
ing to Frost This will push manufactur-
ers to create more maintenance-free
solutions such as lubrication-free
bearings that offer end-users savings
on service and replacement costs and
reduce downtimeldquoOffering a complete line of prod-
ucts with comprehensive services will
be another feather in the cap of ven-
dors looking to widen their consumer
baserdquo notes Frost Industrial Automa-
tion and Process Control Research
Analyst Guru Mahesh
Moore says the trend of outsourcing
manufacturing to regions where labor
and production costs are favorable is
becoming less of a factor
ldquoThe days when cheap labor made
a significant difference in where a prod-
uct is manufactured mdash particularly high
value-added products or high weight
and bulk products mdash are coming to
an end as the cost of transportation
storage and inventory balance out the
benefits of production costs where la-
bor is a smaller percentage of the cost
of manufacturingrdquo Moore says ldquoLocal
manufacturing development will indeed
come to developing countries as their
ability to create markets that generate
economies of scale that support local
production is a clear trend and one that
all manufacturers will pay attention tordquo
Moore says that development of
maintenance-free or predictive tech-
nologies and products will be a sig-
nificant advantage to everyone in the
Bearing amp Coupling Manufacturers Focus
onDEVELOPING Economies
amp EFFICIENCY InnovationBy Amy W Richardson
2 January 2015
Flow Control Magazine
|
gy
Anew study from Frost amp Sullivan (wwwfrostcom) fore-
casts steady growth for the overall bearings and couplings
market based on rapid industrial development in high-growth
regions Specifically Frost predicts development in Mexico
Indonesia Nigeria Turkey Brazil Russia India and Chinawill help boost the bearings amp couplings market from $2206
billion in 2013 to an estimated $2676 billion in 2018
The development of maintenance-freeor predictive technologies will helpboost growth in the bearings market For example SKF is developing products that will automatically notifyusers when a bearing or mechanicalrotating component is approachingthe end of its useful life Pictured hereis an SKF Microlog analyzer a por- table condition monitoring tool
COURTESY SKF
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
improved productivity through simplified solutions The powerful technology and tools ensure repeatable
reliable accurate measurements Easier access to process data allows for better troubleshooting process
optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
For daily product notes visit the lsquoFeatured Productsrsquo section flowcontrolnetworkcom
ON THE WEB
1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3845
FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
and benefits as well as grids of
instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
services provided for the
mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
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THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
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One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
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7232019 Flow Control January 2015
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HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
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FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
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![Page 29: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/29.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 29456 January 2015
Flow Control Magazine
|
y
g
stream path the mixing section and
the downstream impellers when ma-
chine is operated at part-load or even
off-design operating flows will result
in additional compressor performance
problems In such a case both veloc-
ity profiles and pressure variations in
various parts (side-stream path mixing
section etc) will be different resulting
in complicated flow patterns and com-
plex aerodynamics behaviors
Side-Stream CompressorSectional Performance
Typically vendor-supplied compressor
performance curves reflect flange-to-flange performance because that is
what the plant engineers need to
evaluate the proper operation of their
system (for example from suction to
side-stream and from side-stream to
discharge) In many cases compres-
sor vendors also provide the over-
all compressor performance curves
and performance curves for section-1
(from suction to side-stream) and sec-
tion-2 (from side-stream to discharge)
Flange-to-flange data if not interpret-
ed properly can lead to false conclu-
sions about the relative performance
of individual sections of a compression
system For example if side-stream
losses from the flange to mixing sec-
tion are attributed to the downstream
section (section-2) it will cause the
downstream section (section-2) to
appear low in performance while the
upstream section (section-1) will show
high performance levels
An important behavior to con-
sider is when the actual side-stream
pressure is different than the rated
side-stream pressure When the side-
stream pressure is slightly higher than
the outlet pressure of the section-1
it (section-1) shows a relatively higher
performance compared to the real sec-
tion-1 performance In some cases
the performance of section-1 could be
considerably higher than section-2 In
other words when performance is de-
termined flange to flange the higher
flange pressure is seen as extra ldquopseu-
dordquo work done by the section (since this
is an inconsistent thermodynamic vol-
ume) resulting in a relatively high sec-
tional efficiency (section-1 shows a rel-
atively high efficiency) This is the case
for many compressors with side-stream
because the whole system is designed
(or specifically the side-stream location
is selected) in a way aimed at main-
taining the real side-stream pressure(side-stream inlet) above the section-1
outlet pressure because if the real side-
stream pressure becomes lower than
the section-1 outlet pressure the flow
may (theoretically) reverse
This is particularly important when
the side-stream mass flow is much
lower than the mass flow of core-flow
The above-mentioned reasons explain
why in many simulations calcula-
tions and performance reports related
to compressors with side-stream the
section-1 shows a relatively good ef-
ficiency and section-2 appears low in
efficiency
When the side-stream pressure is
slightly lower than the outlet pressure
of the section-1 the section-1 might
show a relatively lower performance
compared to section-2 This could oc-
cur in some recycle services where the
side-stream is actually a recycle flow
with a mass flow around two to five
times the core-flow The side-stream
(recycle) flow is returned from down-
stream of the compressor to be slightly
compressed and recycled to the down-
stream Such a recycled side-stream
compressor can present unique chal-
lenges for design and operation This
kind of machine usually needs very
special operating procedures and very
fine adjustments regarding operating
pressures and flows
Side-Stream Compressor
Performance amp Operation An important consideration is the sen-
sitivity of compressor overall perfor-
mance curve and sectional perfor-
mance curves to the flow ratio (ratio
of side-stream flow to core-flow) and
to the inlet conditions Variations in
the flow and pressure of the main
suction and side-stream inlet should
be controlled within tight tolerances
For compressors with side-stream the ASME PTC-10 code stipulates limits on
flow ratio (side-stream volume to core-
flow volume) The acceptable variation
in volume flow ratio in a compressor
with a side-stream is +-5 percent as
per ASME PTC code The requested
side-stream pressure tolerance is not
usually specified in compressor codes
but it should be around +- 2 percent
(or sometimes +- 25 percent)
Variance in flow ratio impacts the
velocity levels where the two streams
merge Significant variation in the ve-
locity profile upstream of the impeller
changes the incidence on the blade
leading edge of the following impel-
ler This change in incidence leads to a
change in sectional performance over-
all compressor performance and train
efficiency
If the flow ratio is varied between 95
percent and 105 percent (tolerances
specified in the ASME PTC-10 code)
the flange pressure changes accord-
ingly resulting in a change in the sec-
tional performance and overall perfor-
mance The sectional efficiency varies
sometimes more than +- 4 percent
This variance reduces as the flow is de-
creased toward surge However as the
flow is increased toward overload the
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3045wwwflowcontrolnetworkcom January 2015 27
variance increases up to higher values
(even in some cases three to five times
compared to variations near the surge
zone) For example in a case study
for a compressor with side-streams a
+- 5 percent variation in flow ratio and
associated changes (pressures losses
etc) the sectional efficiency reduced by
approximately 34 percent at the rated
flow at allowable operating points at
the end of curve (near the overload
ie choke) efficiency reduced by ap-
proximately 55 percent These results
show that the variation in sectional
performance and overall performance
due to flow ratio is highest at operat-ing points near the overload and low-
est at operating points near the surge
For compressors which work most of
the time at high flow (flow higher than
rated flow and discharge pressure low-
er than rated pressure) the effects of
flow ratio deviations (and subsequently
efficiency reduction) would be higher
than compressors working on the left-
hand side of curve (say with sufficient
margins near the surge)
In the compressor codes (such as
API 617) the compressor power varia-
tions should be maintained below 4
percent However in some applica-
tions clients require tighter tolerances
on the consumed power sometimes
below 2 percent (or even below 15
percent) Some studies suggest while
+- 5 percent of volume flow ratio is
suitable for performance test as per
ASME PTC-10 code some plants re-
quire tighter control on the consumed
power and compressor performance
(lower limits on the efficiency) the tol-
erances on the volume flow ratio could
be tighter than ASME PTC code In this
regard +- 4 percent tolerance can be
suggested on the volume flow ratio (ra-
tio of side-stream flow to core-flow) of
compressors with side-streams
Based on operational experiences
acceptable variations in volume flow
ratio and inlet pressures (suction inlet
and side-stream inlet) of a compressor
with side-streams are +- 4 percent
and +- 2 percent respectively
Another important consideration is
the required adjustments for the flow
ratio (side-stream flow to core-flow)
Compressors with side-stream usually
require fixed side-stream flange pres-
sures For a compressor with some variations in operation conditions (even
small changes) it is not usually pos-
sible to achieve optimum operation by
keeping the flow ratio (side-stream to
core-flow) constant The flow ratio has
to be adjusted according to the inlet
flow at which the machine is operating
in order to get the required correspond-
ing side-stream flange pressure
Thermal changes have also been
known to cause some instability in
centrifugal compressors An example is
the thermal-induced change of resid-
ual unbalance For compressors with
side-streams which feature tempera-
ture differences between core-flow and
side-stream flow the thermal behav-
ior of the compressor is usually more
complex and requires more attention
Heavy Gas ChallengeHeavy gases (such as heavy hydrocar-
bon gases eg propane propylene
MTBE (Methyl Tertiary Butyl Ether))
have very low gas sonic velocities that
produce high Mach numbers in the
aerodynamic flow paths For these
services because of high Mach num-
ber high flow coefficient stages have
very narrow flow maps characterized
by limited surge and choke margins
Compressors with side-streams in
these services present great challeng-
es This is to say the side-streams and
associated mixing further complicate
design operation and performance
prediction because the pressure tem-
perature and flow conditions at each
one of these side-streams as well
as at the exit of the machine require
stringent tolerances to optimize the
overall efficiency and performance
As such it is important to accuratelymodel design operate and moni-
tor performance characteristics of any
impellers diffusers return channels
and generally all flow-path components
in a compressor with side-stream FC
Amin Almasi
is a senior rotating
machine consultant
in Australia He is
a chartered profes- sional engineer of
Engineers Australia
(MIEAust CPEng ndash
Mechanical) and
IMechE (CEng MIMechE) holds
bachelorrsquos and masterrsquos degrees
in Mechanical Engineering and is
a registered professional engineer
in Queensland He specializes in
rotating machines including cen-
trifugal screw and reciprocating
compressors gas turbines steamturbines engines pumps subsea
offshore rotating machines LNG
units condition monitoring and reli-
ability Mr Almasi is an active mem-
ber of Engineers Australia IMechE
ASME and SPE He can be reached
at aminalmasiymailcom
Amin Almasi
Compressor | Gas Flow | Performance Curve | Side-Stream Flow
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3145
The pressure in the stuffing box
containing the packing can be estimat-
ed by the following equation
SBP = [Discharge ndash Suction] 3 + Suction
Pressure at the bottom of the stuff-
ing box will be higher than the suction
pressure but considerably lower than
the discharge pressure It should be
noted this calculation will yield a con-
servative estimate of stuffing box pres-
sure that can be further reduced by
pump design
A hole in the stuffing box serves as
a port for injecting clean fluid that cir-
culates around a lantern ring aligned
under the flush port The fluid flushes
solids back into the process to protect
the packing from abrasive wear If the
clean fluid is injected at a pressure ex-
ceeding that at the bottom of the stuff-
ing box some of it will leak back into
the process and some will leak out to
the atmosphere Recommended flush
injection pressure is 15ndash30 PSI (1ndash2
Bar) greater than the pressure at the
bottom of the stuffing box
Fluid injection is also used to lubri-
cate and cool dry-running packing that
is subject to frictional heat and to pre-
vent air from entering the pump which
reduces flow and operating efficiency
Centrifugal pumps utilize three
types of impellersmdashopen semi-open
and closed (Figures 2 3 amp 4) Open
designs prevent fluids with large solids
from clogging the impellers but at theexpense of pump efficiency Backing
plates on semi-open designs serve to
trap the fluid for more efficient opera-
tion Closed impellers are for use with
clean fluids since solids could ac-
cumulate in the eye which would re-
quire tearing down the pump to remove
them
Single-Stage CentrifugalPumpsSingle-stage centrifugal pumps typi-
cally have good bearing support of the
shaft with few run-out or ldquowhiprdquo prob-
lems However in some cases they
are subject to cavitation This occurs
in the eye of the impeller where the
fluid is under vacuum If the pressure
is low enough it will cause the material
to vaporize forming air or water vapor
bubbles As the fluid passes through
How Pumping Systems Design Affects Sealing Performance
By Chris Boss
8 January 2015
Flow Control Magazine
|
Understanding how different types of pump designs impact
sealing is critical to optimizing efficiency safety and lon-
gevity of the sealing system Used for a wide variety of media
including clear fluids solutions and slurries single-stage
centrifugal pumps are one of the most common
types (Figure 1) Fluid drawn into these pumps
enters the eye of an impeller that spins itto the outside of its container
or volute building pressure as
it moves toward discharge
Some of this fluid will work
its way behind the impeller
where it must be sealed with
compression packing or a
mechanical seal
Figure 1
Figure 2 Figure 3 Figure 4
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3245
the pump under increasing pressure
these bubbles implode sending shock
and vibration through the impeller
adversely affecting the seal This phe-
nomenon can be mitigated by running
the pump at slower speed and higher
pressure at the suction end to prevent
air from entering the fluid
Double-Ended Split-CasePumpsOperating on the same centrifugal prin-
ciple but slightly different geometry are
double-ended split-case pumps (Figure
5) Fluid enters both ends of the pump
and is directed into the eye of an impel-ler which spins it out of the volute to
discharge Packing is installed on both
the shaft and bearing ends so the stuff-
ing box is exposed only to suction pres-
sure which is usually quite low
Axial Flow Pumps Axial flow pumps operate like hydro
turbines in reverse whereby a propeller
(or axial impeller) pushes the fluid to
discharge (Figure 6)
Since the stuffing box is located
downstream of the propeller at the dis-
charge end of the pump the packing is
exposed to the full discharge pressure
Vertical PumpsVertical turbine pumps are typically
flange-mounted on a floor extending
downward into a water-filled sump
hole (Figure 7) Available as single- or
multi-stage pumps they feature an
impeller or series of impellers rotated
simultaneously by a single shaft The
impellers increase the pressure of the
upward flow subjecting the stuffing box
to full discharge pressure
Vertical pumps can be quite long so
inadequate bearing support can cause
the shaft to run out This can induce
undesirable lateral motion on the pack-
ing Worse the packing may be forced
to serve both as a bearing and a seal To
withstand these conditions the packing
should be resilient elastic and resistant
to deformation These properties rule
out packing such as graphite foil in favor
of fiber-based materials
Multi-Stage PumpsMulti-stage pumps are used for high-
pressure applications such as feeding
the boilers in steam-powered generating
plants Stuffing box pressure can vary
with pump design and number of stag-
es Designed for clean fluids and high
operating speeds these pumps typically
have high- and low-pressure ends with ahydraulic pressure equalization line run-
ning between the stuffing boxes
Like vertical pumps multi-stage
pumps feature a series of impellers to
build fluid discharge pressure In the
case of the six-stage pump pictured in
Figure 8 fluid enters at the drive end
where a stuffing box is exposed to suc-
tion pressure Channeled from one
impeller to the next through the pump
casting the fluid can reach extremely
high pressures at discharge
A second stuffing box located at the
bearing end is exposed to an intermedi-
ate pressure from the third impeller This
pressure is greater than the suction pres-
sure but much less than the discharge
pressure which can reach 2000 PSI
Fortunately the stuffing boxes in
these pumps are not exposed to dis-
charge pressures and typically see be-
low 500 PSI which is within the range
of some packing materials
wwwflowcontrolnetworkcom January 2015 29
Figure 5
Figure 6
Figure 7
Figure 8
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 33450 January 2015
Flow Control Magazine
| Gear PumpsPositive-displacement or gear pumps
operate on a different principle than
centrifugal pumps In external gear
pumps the fluid flows around the out-
side of the gears the intermeshing
of which forces it through the pump
to discharge (Figure 9) This design
makes these pumps particularly suit-
able for use with highly viscous fluids
such as resins emulsions syrups and
adhesives As such they are used for
transfer or metering applications
It should be noted gear pumps will
continue to displace fluid as long as
their shafts are turning which can pose
a problem if a clog occurs at the dis-
charge The resulting buildup of pres-
sure can blow out seals and damage
the pump Therefore most gear pumps
have pressure relief valves to divert
fluid back to the suction side for re-
circulation through the pump Internal
gear pumps operate slightly differently
but also have pressure relief valves to
prevent damage from excessive pres-
sure (Figure 10) In both external and
internal gear pumps the maximum
stuffing box pressure is determined by
these valves
Other rotating equipment includes
mixersagitators which are similar to
pumps in terms of the speeds to which
the packing is exposed There are ba-
sically three types of mixersagitators
top- bottom- and side-entry Top-entry
models are subject to the same con-
cerns about shaft run-out ldquowhiprdquo and
lateral forces on the paddles that are
encountered in some vertical pumps
Although some fluid may splash onto
the packing these mixers basically run
dry so the packing must have the abil-
ity to dissipate the resulting frictional
heat
In bottom-entry mixers the packing
is always exposed to fluid and may also
be exposed to solids requiring abra-
sion-resistance If the seal fails the en-
tire contents of the tank will eventually
drain out onto the bearings the floor
and other components under the stuff-
ing box
The packing in side-entry mixers may
be fully or intermittently exposed to flu-
id as well as side loading and vibration
Aside from media temperature
speed and other application variables
the configurations and operating prin-
ciples of rotary-type pumps exert differ-
ent forces on the seals used to keep
them from leaking These forces can
spell the difference between accept-
able seal performance and failure
Understanding these differences has
important implications that should be
taken into account to assure proper
sealing selection for long-term trou-
ble-free performance FC
wwwgarlockcom
Chris Boss is
a senior applica-
tions engineer for
Garlock Sealing
Technologies in
Palmyra NY He
has held various
positions in produc-
tion engineering
product development and applica-
tions engineering for the companyrsquos
compression packing division He
is a BSME graduate of the State
University of New York at Buffalo Mr
Boss can be reached at 800 448-
6688 or chrisbossgarlockcom
Chris Boss
Cavitation | Centrifugal Pump | Pump Packing | Sealing System
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Figure 9
Figure 10
Aside from media temperature speed and
other application variables the configurations
and operating principles of rotary-type
pumps exert different forces on the seals used
to keep them from leaking These forces can
spell the difference between acceptable seal
performance and failure
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3445
NS IDERNDUSTRIAL AUTOMATION + PROCESS CONTROL
WANT
INFORMATION
ON THE
automationindustry
SUBSCRIBE NOW at wwwiainsidercouk
Published by Spitzer and Boyes LLC Write in 15 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
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Frost says the push from developing
economies is important as the market
is technologically mature and seeing
restricted growth in developed econo-
mies This is particularly true in Europe
and North America where recent finan-
cial insta-
bility has
reduced capital expenditure across end-
user industries
Bill Moore senior vice president of
sales development and channel man-
agement for global bearings manufac-
turer SKF says ldquosmartrdquo products and
the expansion of robust reliability pro-
grams are helping to drive new invest-
ment particularly in developed coun-
tries where the cost to compete is
high Frost says the magnitude of
the existing global installed base will
strengthen the need for replacement
and upgrades adding to market de-
mand as well
Frost says despite the potential
in developing economies the focus
on price as a product differentiator
may lead to intense price pressures
among manufacturers and bring down
the value of the overall market in the
short term The growing trend among
consumers to choose low-cost Chinese
imports will complicate this challenge
As price and quality become stan-
dardized across the globe customers
will base more of their purchasing deci-
sions on value-added services accord-
ing to Frost This will push manufactur-
ers to create more maintenance-free
solutions such as lubrication-free
bearings that offer end-users savings
on service and replacement costs and
reduce downtimeldquoOffering a complete line of prod-
ucts with comprehensive services will
be another feather in the cap of ven-
dors looking to widen their consumer
baserdquo notes Frost Industrial Automa-
tion and Process Control Research
Analyst Guru Mahesh
Moore says the trend of outsourcing
manufacturing to regions where labor
and production costs are favorable is
becoming less of a factor
ldquoThe days when cheap labor made
a significant difference in where a prod-
uct is manufactured mdash particularly high
value-added products or high weight
and bulk products mdash are coming to
an end as the cost of transportation
storage and inventory balance out the
benefits of production costs where la-
bor is a smaller percentage of the cost
of manufacturingrdquo Moore says ldquoLocal
manufacturing development will indeed
come to developing countries as their
ability to create markets that generate
economies of scale that support local
production is a clear trend and one that
all manufacturers will pay attention tordquo
Moore says that development of
maintenance-free or predictive tech-
nologies and products will be a sig-
nificant advantage to everyone in the
Bearing amp Coupling Manufacturers Focus
onDEVELOPING Economies
amp EFFICIENCY InnovationBy Amy W Richardson
2 January 2015
Flow Control Magazine
|
gy
Anew study from Frost amp Sullivan (wwwfrostcom) fore-
casts steady growth for the overall bearings and couplings
market based on rapid industrial development in high-growth
regions Specifically Frost predicts development in Mexico
Indonesia Nigeria Turkey Brazil Russia India and Chinawill help boost the bearings amp couplings market from $2206
billion in 2013 to an estimated $2676 billion in 2018
The development of maintenance-freeor predictive technologies will helpboost growth in the bearings market For example SKF is developing products that will automatically notifyusers when a bearing or mechanicalrotating component is approachingthe end of its useful life Pictured hereis an SKF Microlog analyzer a por- table condition monitoring tool
COURTESY SKF
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
improved productivity through simplified solutions The powerful technology and tools ensure repeatable
reliable accurate measurements Easier access to process data allows for better troubleshooting process
optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
For daily product notes visit the lsquoFeatured Productsrsquo section flowcontrolnetworkcom
ON THE WEB
1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
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FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
and benefits as well as grids of
instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
services provided for the
mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
Brought to you by Beamex
Your Source For Fluid Handling Videos
Go towwwflowcontrolnetworkcomfreeinfo
Select appropriate issue ofFlow Control Magazine
Select advertisements thatinterest you
Enter your email amp clickldquoSubmit Requestrdquo
1
2
3
4
PRODUCT
INFORMATION
ONLINE
Follow these 4 steps to receive freeproduct information from suppliers
FREE
FEATURED VIDEO How to Calibrate aPressure Measurement Loop
For more information about FlowTube
sponsor packs email FlowControlGrandViewMediacom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4245
THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
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Title _________________________________________________________________
Company _____________________________________________________________
AddressCityStateZip __________________________________________________
______________________________________________________________________
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One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545
![Page 30: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/30.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3045wwwflowcontrolnetworkcom January 2015 27
variance increases up to higher values
(even in some cases three to five times
compared to variations near the surge
zone) For example in a case study
for a compressor with side-streams a
+- 5 percent variation in flow ratio and
associated changes (pressures losses
etc) the sectional efficiency reduced by
approximately 34 percent at the rated
flow at allowable operating points at
the end of curve (near the overload
ie choke) efficiency reduced by ap-
proximately 55 percent These results
show that the variation in sectional
performance and overall performance
due to flow ratio is highest at operat-ing points near the overload and low-
est at operating points near the surge
For compressors which work most of
the time at high flow (flow higher than
rated flow and discharge pressure low-
er than rated pressure) the effects of
flow ratio deviations (and subsequently
efficiency reduction) would be higher
than compressors working on the left-
hand side of curve (say with sufficient
margins near the surge)
In the compressor codes (such as
API 617) the compressor power varia-
tions should be maintained below 4
percent However in some applica-
tions clients require tighter tolerances
on the consumed power sometimes
below 2 percent (or even below 15
percent) Some studies suggest while
+- 5 percent of volume flow ratio is
suitable for performance test as per
ASME PTC-10 code some plants re-
quire tighter control on the consumed
power and compressor performance
(lower limits on the efficiency) the tol-
erances on the volume flow ratio could
be tighter than ASME PTC code In this
regard +- 4 percent tolerance can be
suggested on the volume flow ratio (ra-
tio of side-stream flow to core-flow) of
compressors with side-streams
Based on operational experiences
acceptable variations in volume flow
ratio and inlet pressures (suction inlet
and side-stream inlet) of a compressor
with side-streams are +- 4 percent
and +- 2 percent respectively
Another important consideration is
the required adjustments for the flow
ratio (side-stream flow to core-flow)
Compressors with side-stream usually
require fixed side-stream flange pres-
sures For a compressor with some variations in operation conditions (even
small changes) it is not usually pos-
sible to achieve optimum operation by
keeping the flow ratio (side-stream to
core-flow) constant The flow ratio has
to be adjusted according to the inlet
flow at which the machine is operating
in order to get the required correspond-
ing side-stream flange pressure
Thermal changes have also been
known to cause some instability in
centrifugal compressors An example is
the thermal-induced change of resid-
ual unbalance For compressors with
side-streams which feature tempera-
ture differences between core-flow and
side-stream flow the thermal behav-
ior of the compressor is usually more
complex and requires more attention
Heavy Gas ChallengeHeavy gases (such as heavy hydrocar-
bon gases eg propane propylene
MTBE (Methyl Tertiary Butyl Ether))
have very low gas sonic velocities that
produce high Mach numbers in the
aerodynamic flow paths For these
services because of high Mach num-
ber high flow coefficient stages have
very narrow flow maps characterized
by limited surge and choke margins
Compressors with side-streams in
these services present great challeng-
es This is to say the side-streams and
associated mixing further complicate
design operation and performance
prediction because the pressure tem-
perature and flow conditions at each
one of these side-streams as well
as at the exit of the machine require
stringent tolerances to optimize the
overall efficiency and performance
As such it is important to accuratelymodel design operate and moni-
tor performance characteristics of any
impellers diffusers return channels
and generally all flow-path components
in a compressor with side-stream FC
Amin Almasi
is a senior rotating
machine consultant
in Australia He is
a chartered profes- sional engineer of
Engineers Australia
(MIEAust CPEng ndash
Mechanical) and
IMechE (CEng MIMechE) holds
bachelorrsquos and masterrsquos degrees
in Mechanical Engineering and is
a registered professional engineer
in Queensland He specializes in
rotating machines including cen-
trifugal screw and reciprocating
compressors gas turbines steamturbines engines pumps subsea
offshore rotating machines LNG
units condition monitoring and reli-
ability Mr Almasi is an active mem-
ber of Engineers Australia IMechE
ASME and SPE He can be reached
at aminalmasiymailcom
Amin Almasi
Compressor | Gas Flow | Performance Curve | Side-Stream Flow
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3145
The pressure in the stuffing box
containing the packing can be estimat-
ed by the following equation
SBP = [Discharge ndash Suction] 3 + Suction
Pressure at the bottom of the stuff-
ing box will be higher than the suction
pressure but considerably lower than
the discharge pressure It should be
noted this calculation will yield a con-
servative estimate of stuffing box pres-
sure that can be further reduced by
pump design
A hole in the stuffing box serves as
a port for injecting clean fluid that cir-
culates around a lantern ring aligned
under the flush port The fluid flushes
solids back into the process to protect
the packing from abrasive wear If the
clean fluid is injected at a pressure ex-
ceeding that at the bottom of the stuff-
ing box some of it will leak back into
the process and some will leak out to
the atmosphere Recommended flush
injection pressure is 15ndash30 PSI (1ndash2
Bar) greater than the pressure at the
bottom of the stuffing box
Fluid injection is also used to lubri-
cate and cool dry-running packing that
is subject to frictional heat and to pre-
vent air from entering the pump which
reduces flow and operating efficiency
Centrifugal pumps utilize three
types of impellersmdashopen semi-open
and closed (Figures 2 3 amp 4) Open
designs prevent fluids with large solids
from clogging the impellers but at theexpense of pump efficiency Backing
plates on semi-open designs serve to
trap the fluid for more efficient opera-
tion Closed impellers are for use with
clean fluids since solids could ac-
cumulate in the eye which would re-
quire tearing down the pump to remove
them
Single-Stage CentrifugalPumpsSingle-stage centrifugal pumps typi-
cally have good bearing support of the
shaft with few run-out or ldquowhiprdquo prob-
lems However in some cases they
are subject to cavitation This occurs
in the eye of the impeller where the
fluid is under vacuum If the pressure
is low enough it will cause the material
to vaporize forming air or water vapor
bubbles As the fluid passes through
How Pumping Systems Design Affects Sealing Performance
By Chris Boss
8 January 2015
Flow Control Magazine
|
Understanding how different types of pump designs impact
sealing is critical to optimizing efficiency safety and lon-
gevity of the sealing system Used for a wide variety of media
including clear fluids solutions and slurries single-stage
centrifugal pumps are one of the most common
types (Figure 1) Fluid drawn into these pumps
enters the eye of an impeller that spins itto the outside of its container
or volute building pressure as
it moves toward discharge
Some of this fluid will work
its way behind the impeller
where it must be sealed with
compression packing or a
mechanical seal
Figure 1
Figure 2 Figure 3 Figure 4
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3245
the pump under increasing pressure
these bubbles implode sending shock
and vibration through the impeller
adversely affecting the seal This phe-
nomenon can be mitigated by running
the pump at slower speed and higher
pressure at the suction end to prevent
air from entering the fluid
Double-Ended Split-CasePumpsOperating on the same centrifugal prin-
ciple but slightly different geometry are
double-ended split-case pumps (Figure
5) Fluid enters both ends of the pump
and is directed into the eye of an impel-ler which spins it out of the volute to
discharge Packing is installed on both
the shaft and bearing ends so the stuff-
ing box is exposed only to suction pres-
sure which is usually quite low
Axial Flow Pumps Axial flow pumps operate like hydro
turbines in reverse whereby a propeller
(or axial impeller) pushes the fluid to
discharge (Figure 6)
Since the stuffing box is located
downstream of the propeller at the dis-
charge end of the pump the packing is
exposed to the full discharge pressure
Vertical PumpsVertical turbine pumps are typically
flange-mounted on a floor extending
downward into a water-filled sump
hole (Figure 7) Available as single- or
multi-stage pumps they feature an
impeller or series of impellers rotated
simultaneously by a single shaft The
impellers increase the pressure of the
upward flow subjecting the stuffing box
to full discharge pressure
Vertical pumps can be quite long so
inadequate bearing support can cause
the shaft to run out This can induce
undesirable lateral motion on the pack-
ing Worse the packing may be forced
to serve both as a bearing and a seal To
withstand these conditions the packing
should be resilient elastic and resistant
to deformation These properties rule
out packing such as graphite foil in favor
of fiber-based materials
Multi-Stage PumpsMulti-stage pumps are used for high-
pressure applications such as feeding
the boilers in steam-powered generating
plants Stuffing box pressure can vary
with pump design and number of stag-
es Designed for clean fluids and high
operating speeds these pumps typically
have high- and low-pressure ends with ahydraulic pressure equalization line run-
ning between the stuffing boxes
Like vertical pumps multi-stage
pumps feature a series of impellers to
build fluid discharge pressure In the
case of the six-stage pump pictured in
Figure 8 fluid enters at the drive end
where a stuffing box is exposed to suc-
tion pressure Channeled from one
impeller to the next through the pump
casting the fluid can reach extremely
high pressures at discharge
A second stuffing box located at the
bearing end is exposed to an intermedi-
ate pressure from the third impeller This
pressure is greater than the suction pres-
sure but much less than the discharge
pressure which can reach 2000 PSI
Fortunately the stuffing boxes in
these pumps are not exposed to dis-
charge pressures and typically see be-
low 500 PSI which is within the range
of some packing materials
wwwflowcontrolnetworkcom January 2015 29
Figure 5
Figure 6
Figure 7
Figure 8
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 33450 January 2015
Flow Control Magazine
| Gear PumpsPositive-displacement or gear pumps
operate on a different principle than
centrifugal pumps In external gear
pumps the fluid flows around the out-
side of the gears the intermeshing
of which forces it through the pump
to discharge (Figure 9) This design
makes these pumps particularly suit-
able for use with highly viscous fluids
such as resins emulsions syrups and
adhesives As such they are used for
transfer or metering applications
It should be noted gear pumps will
continue to displace fluid as long as
their shafts are turning which can pose
a problem if a clog occurs at the dis-
charge The resulting buildup of pres-
sure can blow out seals and damage
the pump Therefore most gear pumps
have pressure relief valves to divert
fluid back to the suction side for re-
circulation through the pump Internal
gear pumps operate slightly differently
but also have pressure relief valves to
prevent damage from excessive pres-
sure (Figure 10) In both external and
internal gear pumps the maximum
stuffing box pressure is determined by
these valves
Other rotating equipment includes
mixersagitators which are similar to
pumps in terms of the speeds to which
the packing is exposed There are ba-
sically three types of mixersagitators
top- bottom- and side-entry Top-entry
models are subject to the same con-
cerns about shaft run-out ldquowhiprdquo and
lateral forces on the paddles that are
encountered in some vertical pumps
Although some fluid may splash onto
the packing these mixers basically run
dry so the packing must have the abil-
ity to dissipate the resulting frictional
heat
In bottom-entry mixers the packing
is always exposed to fluid and may also
be exposed to solids requiring abra-
sion-resistance If the seal fails the en-
tire contents of the tank will eventually
drain out onto the bearings the floor
and other components under the stuff-
ing box
The packing in side-entry mixers may
be fully or intermittently exposed to flu-
id as well as side loading and vibration
Aside from media temperature
speed and other application variables
the configurations and operating prin-
ciples of rotary-type pumps exert differ-
ent forces on the seals used to keep
them from leaking These forces can
spell the difference between accept-
able seal performance and failure
Understanding these differences has
important implications that should be
taken into account to assure proper
sealing selection for long-term trou-
ble-free performance FC
wwwgarlockcom
Chris Boss is
a senior applica-
tions engineer for
Garlock Sealing
Technologies in
Palmyra NY He
has held various
positions in produc-
tion engineering
product development and applica-
tions engineering for the companyrsquos
compression packing division He
is a BSME graduate of the State
University of New York at Buffalo Mr
Boss can be reached at 800 448-
6688 or chrisbossgarlockcom
Chris Boss
Cavitation | Centrifugal Pump | Pump Packing | Sealing System
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Figure 9
Figure 10
Aside from media temperature speed and
other application variables the configurations
and operating principles of rotary-type
pumps exert different forces on the seals used
to keep them from leaking These forces can
spell the difference between acceptable seal
performance and failure
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3445
NS IDERNDUSTRIAL AUTOMATION + PROCESS CONTROL
WANT
INFORMATION
ON THE
automationindustry
SUBSCRIBE NOW at wwwiainsidercouk
Published by Spitzer and Boyes LLC Write in 15 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3545
Frost says the push from developing
economies is important as the market
is technologically mature and seeing
restricted growth in developed econo-
mies This is particularly true in Europe
and North America where recent finan-
cial insta-
bility has
reduced capital expenditure across end-
user industries
Bill Moore senior vice president of
sales development and channel man-
agement for global bearings manufac-
turer SKF says ldquosmartrdquo products and
the expansion of robust reliability pro-
grams are helping to drive new invest-
ment particularly in developed coun-
tries where the cost to compete is
high Frost says the magnitude of
the existing global installed base will
strengthen the need for replacement
and upgrades adding to market de-
mand as well
Frost says despite the potential
in developing economies the focus
on price as a product differentiator
may lead to intense price pressures
among manufacturers and bring down
the value of the overall market in the
short term The growing trend among
consumers to choose low-cost Chinese
imports will complicate this challenge
As price and quality become stan-
dardized across the globe customers
will base more of their purchasing deci-
sions on value-added services accord-
ing to Frost This will push manufactur-
ers to create more maintenance-free
solutions such as lubrication-free
bearings that offer end-users savings
on service and replacement costs and
reduce downtimeldquoOffering a complete line of prod-
ucts with comprehensive services will
be another feather in the cap of ven-
dors looking to widen their consumer
baserdquo notes Frost Industrial Automa-
tion and Process Control Research
Analyst Guru Mahesh
Moore says the trend of outsourcing
manufacturing to regions where labor
and production costs are favorable is
becoming less of a factor
ldquoThe days when cheap labor made
a significant difference in where a prod-
uct is manufactured mdash particularly high
value-added products or high weight
and bulk products mdash are coming to
an end as the cost of transportation
storage and inventory balance out the
benefits of production costs where la-
bor is a smaller percentage of the cost
of manufacturingrdquo Moore says ldquoLocal
manufacturing development will indeed
come to developing countries as their
ability to create markets that generate
economies of scale that support local
production is a clear trend and one that
all manufacturers will pay attention tordquo
Moore says that development of
maintenance-free or predictive tech-
nologies and products will be a sig-
nificant advantage to everyone in the
Bearing amp Coupling Manufacturers Focus
onDEVELOPING Economies
amp EFFICIENCY InnovationBy Amy W Richardson
2 January 2015
Flow Control Magazine
|
gy
Anew study from Frost amp Sullivan (wwwfrostcom) fore-
casts steady growth for the overall bearings and couplings
market based on rapid industrial development in high-growth
regions Specifically Frost predicts development in Mexico
Indonesia Nigeria Turkey Brazil Russia India and Chinawill help boost the bearings amp couplings market from $2206
billion in 2013 to an estimated $2676 billion in 2018
The development of maintenance-freeor predictive technologies will helpboost growth in the bearings market For example SKF is developing products that will automatically notifyusers when a bearing or mechanicalrotating component is approachingthe end of its useful life Pictured hereis an SKF Microlog analyzer a por- table condition monitoring tool
COURTESY SKF
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
improved productivity through simplified solutions The powerful technology and tools ensure repeatable
reliable accurate measurements Easier access to process data allows for better troubleshooting process
optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
For daily product notes visit the lsquoFeatured Productsrsquo section flowcontrolnetworkcom
ON THE WEB
1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3845
FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
and benefits as well as grids of
instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
services provided for the
mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
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7232019 Flow Control January 2015
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THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
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Signature _____________________________________ Date _________________
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One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
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HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
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![Page 31: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/31.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3145
The pressure in the stuffing box
containing the packing can be estimat-
ed by the following equation
SBP = [Discharge ndash Suction] 3 + Suction
Pressure at the bottom of the stuff-
ing box will be higher than the suction
pressure but considerably lower than
the discharge pressure It should be
noted this calculation will yield a con-
servative estimate of stuffing box pres-
sure that can be further reduced by
pump design
A hole in the stuffing box serves as
a port for injecting clean fluid that cir-
culates around a lantern ring aligned
under the flush port The fluid flushes
solids back into the process to protect
the packing from abrasive wear If the
clean fluid is injected at a pressure ex-
ceeding that at the bottom of the stuff-
ing box some of it will leak back into
the process and some will leak out to
the atmosphere Recommended flush
injection pressure is 15ndash30 PSI (1ndash2
Bar) greater than the pressure at the
bottom of the stuffing box
Fluid injection is also used to lubri-
cate and cool dry-running packing that
is subject to frictional heat and to pre-
vent air from entering the pump which
reduces flow and operating efficiency
Centrifugal pumps utilize three
types of impellersmdashopen semi-open
and closed (Figures 2 3 amp 4) Open
designs prevent fluids with large solids
from clogging the impellers but at theexpense of pump efficiency Backing
plates on semi-open designs serve to
trap the fluid for more efficient opera-
tion Closed impellers are for use with
clean fluids since solids could ac-
cumulate in the eye which would re-
quire tearing down the pump to remove
them
Single-Stage CentrifugalPumpsSingle-stage centrifugal pumps typi-
cally have good bearing support of the
shaft with few run-out or ldquowhiprdquo prob-
lems However in some cases they
are subject to cavitation This occurs
in the eye of the impeller where the
fluid is under vacuum If the pressure
is low enough it will cause the material
to vaporize forming air or water vapor
bubbles As the fluid passes through
How Pumping Systems Design Affects Sealing Performance
By Chris Boss
8 January 2015
Flow Control Magazine
|
Understanding how different types of pump designs impact
sealing is critical to optimizing efficiency safety and lon-
gevity of the sealing system Used for a wide variety of media
including clear fluids solutions and slurries single-stage
centrifugal pumps are one of the most common
types (Figure 1) Fluid drawn into these pumps
enters the eye of an impeller that spins itto the outside of its container
or volute building pressure as
it moves toward discharge
Some of this fluid will work
its way behind the impeller
where it must be sealed with
compression packing or a
mechanical seal
Figure 1
Figure 2 Figure 3 Figure 4
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3245
the pump under increasing pressure
these bubbles implode sending shock
and vibration through the impeller
adversely affecting the seal This phe-
nomenon can be mitigated by running
the pump at slower speed and higher
pressure at the suction end to prevent
air from entering the fluid
Double-Ended Split-CasePumpsOperating on the same centrifugal prin-
ciple but slightly different geometry are
double-ended split-case pumps (Figure
5) Fluid enters both ends of the pump
and is directed into the eye of an impel-ler which spins it out of the volute to
discharge Packing is installed on both
the shaft and bearing ends so the stuff-
ing box is exposed only to suction pres-
sure which is usually quite low
Axial Flow Pumps Axial flow pumps operate like hydro
turbines in reverse whereby a propeller
(or axial impeller) pushes the fluid to
discharge (Figure 6)
Since the stuffing box is located
downstream of the propeller at the dis-
charge end of the pump the packing is
exposed to the full discharge pressure
Vertical PumpsVertical turbine pumps are typically
flange-mounted on a floor extending
downward into a water-filled sump
hole (Figure 7) Available as single- or
multi-stage pumps they feature an
impeller or series of impellers rotated
simultaneously by a single shaft The
impellers increase the pressure of the
upward flow subjecting the stuffing box
to full discharge pressure
Vertical pumps can be quite long so
inadequate bearing support can cause
the shaft to run out This can induce
undesirable lateral motion on the pack-
ing Worse the packing may be forced
to serve both as a bearing and a seal To
withstand these conditions the packing
should be resilient elastic and resistant
to deformation These properties rule
out packing such as graphite foil in favor
of fiber-based materials
Multi-Stage PumpsMulti-stage pumps are used for high-
pressure applications such as feeding
the boilers in steam-powered generating
plants Stuffing box pressure can vary
with pump design and number of stag-
es Designed for clean fluids and high
operating speeds these pumps typically
have high- and low-pressure ends with ahydraulic pressure equalization line run-
ning between the stuffing boxes
Like vertical pumps multi-stage
pumps feature a series of impellers to
build fluid discharge pressure In the
case of the six-stage pump pictured in
Figure 8 fluid enters at the drive end
where a stuffing box is exposed to suc-
tion pressure Channeled from one
impeller to the next through the pump
casting the fluid can reach extremely
high pressures at discharge
A second stuffing box located at the
bearing end is exposed to an intermedi-
ate pressure from the third impeller This
pressure is greater than the suction pres-
sure but much less than the discharge
pressure which can reach 2000 PSI
Fortunately the stuffing boxes in
these pumps are not exposed to dis-
charge pressures and typically see be-
low 500 PSI which is within the range
of some packing materials
wwwflowcontrolnetworkcom January 2015 29
Figure 5
Figure 6
Figure 7
Figure 8
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 33450 January 2015
Flow Control Magazine
| Gear PumpsPositive-displacement or gear pumps
operate on a different principle than
centrifugal pumps In external gear
pumps the fluid flows around the out-
side of the gears the intermeshing
of which forces it through the pump
to discharge (Figure 9) This design
makes these pumps particularly suit-
able for use with highly viscous fluids
such as resins emulsions syrups and
adhesives As such they are used for
transfer or metering applications
It should be noted gear pumps will
continue to displace fluid as long as
their shafts are turning which can pose
a problem if a clog occurs at the dis-
charge The resulting buildup of pres-
sure can blow out seals and damage
the pump Therefore most gear pumps
have pressure relief valves to divert
fluid back to the suction side for re-
circulation through the pump Internal
gear pumps operate slightly differently
but also have pressure relief valves to
prevent damage from excessive pres-
sure (Figure 10) In both external and
internal gear pumps the maximum
stuffing box pressure is determined by
these valves
Other rotating equipment includes
mixersagitators which are similar to
pumps in terms of the speeds to which
the packing is exposed There are ba-
sically three types of mixersagitators
top- bottom- and side-entry Top-entry
models are subject to the same con-
cerns about shaft run-out ldquowhiprdquo and
lateral forces on the paddles that are
encountered in some vertical pumps
Although some fluid may splash onto
the packing these mixers basically run
dry so the packing must have the abil-
ity to dissipate the resulting frictional
heat
In bottom-entry mixers the packing
is always exposed to fluid and may also
be exposed to solids requiring abra-
sion-resistance If the seal fails the en-
tire contents of the tank will eventually
drain out onto the bearings the floor
and other components under the stuff-
ing box
The packing in side-entry mixers may
be fully or intermittently exposed to flu-
id as well as side loading and vibration
Aside from media temperature
speed and other application variables
the configurations and operating prin-
ciples of rotary-type pumps exert differ-
ent forces on the seals used to keep
them from leaking These forces can
spell the difference between accept-
able seal performance and failure
Understanding these differences has
important implications that should be
taken into account to assure proper
sealing selection for long-term trou-
ble-free performance FC
wwwgarlockcom
Chris Boss is
a senior applica-
tions engineer for
Garlock Sealing
Technologies in
Palmyra NY He
has held various
positions in produc-
tion engineering
product development and applica-
tions engineering for the companyrsquos
compression packing division He
is a BSME graduate of the State
University of New York at Buffalo Mr
Boss can be reached at 800 448-
6688 or chrisbossgarlockcom
Chris Boss
Cavitation | Centrifugal Pump | Pump Packing | Sealing System
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Figure 9
Figure 10
Aside from media temperature speed and
other application variables the configurations
and operating principles of rotary-type
pumps exert different forces on the seals used
to keep them from leaking These forces can
spell the difference between acceptable seal
performance and failure
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3445
NS IDERNDUSTRIAL AUTOMATION + PROCESS CONTROL
WANT
INFORMATION
ON THE
automationindustry
SUBSCRIBE NOW at wwwiainsidercouk
Published by Spitzer and Boyes LLC Write in 15 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3545
Frost says the push from developing
economies is important as the market
is technologically mature and seeing
restricted growth in developed econo-
mies This is particularly true in Europe
and North America where recent finan-
cial insta-
bility has
reduced capital expenditure across end-
user industries
Bill Moore senior vice president of
sales development and channel man-
agement for global bearings manufac-
turer SKF says ldquosmartrdquo products and
the expansion of robust reliability pro-
grams are helping to drive new invest-
ment particularly in developed coun-
tries where the cost to compete is
high Frost says the magnitude of
the existing global installed base will
strengthen the need for replacement
and upgrades adding to market de-
mand as well
Frost says despite the potential
in developing economies the focus
on price as a product differentiator
may lead to intense price pressures
among manufacturers and bring down
the value of the overall market in the
short term The growing trend among
consumers to choose low-cost Chinese
imports will complicate this challenge
As price and quality become stan-
dardized across the globe customers
will base more of their purchasing deci-
sions on value-added services accord-
ing to Frost This will push manufactur-
ers to create more maintenance-free
solutions such as lubrication-free
bearings that offer end-users savings
on service and replacement costs and
reduce downtimeldquoOffering a complete line of prod-
ucts with comprehensive services will
be another feather in the cap of ven-
dors looking to widen their consumer
baserdquo notes Frost Industrial Automa-
tion and Process Control Research
Analyst Guru Mahesh
Moore says the trend of outsourcing
manufacturing to regions where labor
and production costs are favorable is
becoming less of a factor
ldquoThe days when cheap labor made
a significant difference in where a prod-
uct is manufactured mdash particularly high
value-added products or high weight
and bulk products mdash are coming to
an end as the cost of transportation
storage and inventory balance out the
benefits of production costs where la-
bor is a smaller percentage of the cost
of manufacturingrdquo Moore says ldquoLocal
manufacturing development will indeed
come to developing countries as their
ability to create markets that generate
economies of scale that support local
production is a clear trend and one that
all manufacturers will pay attention tordquo
Moore says that development of
maintenance-free or predictive tech-
nologies and products will be a sig-
nificant advantage to everyone in the
Bearing amp Coupling Manufacturers Focus
onDEVELOPING Economies
amp EFFICIENCY InnovationBy Amy W Richardson
2 January 2015
Flow Control Magazine
|
gy
Anew study from Frost amp Sullivan (wwwfrostcom) fore-
casts steady growth for the overall bearings and couplings
market based on rapid industrial development in high-growth
regions Specifically Frost predicts development in Mexico
Indonesia Nigeria Turkey Brazil Russia India and Chinawill help boost the bearings amp couplings market from $2206
billion in 2013 to an estimated $2676 billion in 2018
The development of maintenance-freeor predictive technologies will helpboost growth in the bearings market For example SKF is developing products that will automatically notifyusers when a bearing or mechanicalrotating component is approachingthe end of its useful life Pictured hereis an SKF Microlog analyzer a por- table condition monitoring tool
COURTESY SKF
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
improved productivity through simplified solutions The powerful technology and tools ensure repeatable
reliable accurate measurements Easier access to process data allows for better troubleshooting process
optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
For daily product notes visit the lsquoFeatured Productsrsquo section flowcontrolnetworkcom
ON THE WEB
1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3845
FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
and benefits as well as grids of
instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
services provided for the
mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
Brought to you by Beamex
Your Source For Fluid Handling Videos
Go towwwflowcontrolnetworkcomfreeinfo
Select appropriate issue ofFlow Control Magazine
Select advertisements thatinterest you
Enter your email amp clickldquoSubmit Requestrdquo
1
2
3
4
PRODUCT
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ONLINE
Follow these 4 steps to receive freeproduct information from suppliers
FREE
FEATURED VIDEO How to Calibrate aPressure Measurement Loop
For more information about FlowTube
sponsor packs email FlowControlGrandViewMediacom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4245
THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
Name ________________________________________________________________
Title _________________________________________________________________
Company _____________________________________________________________
AddressCityStateZip __________________________________________________
______________________________________________________________________
Phone ________________________________________________________________
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One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545
![Page 32: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/32.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3245
the pump under increasing pressure
these bubbles implode sending shock
and vibration through the impeller
adversely affecting the seal This phe-
nomenon can be mitigated by running
the pump at slower speed and higher
pressure at the suction end to prevent
air from entering the fluid
Double-Ended Split-CasePumpsOperating on the same centrifugal prin-
ciple but slightly different geometry are
double-ended split-case pumps (Figure
5) Fluid enters both ends of the pump
and is directed into the eye of an impel-ler which spins it out of the volute to
discharge Packing is installed on both
the shaft and bearing ends so the stuff-
ing box is exposed only to suction pres-
sure which is usually quite low
Axial Flow Pumps Axial flow pumps operate like hydro
turbines in reverse whereby a propeller
(or axial impeller) pushes the fluid to
discharge (Figure 6)
Since the stuffing box is located
downstream of the propeller at the dis-
charge end of the pump the packing is
exposed to the full discharge pressure
Vertical PumpsVertical turbine pumps are typically
flange-mounted on a floor extending
downward into a water-filled sump
hole (Figure 7) Available as single- or
multi-stage pumps they feature an
impeller or series of impellers rotated
simultaneously by a single shaft The
impellers increase the pressure of the
upward flow subjecting the stuffing box
to full discharge pressure
Vertical pumps can be quite long so
inadequate bearing support can cause
the shaft to run out This can induce
undesirable lateral motion on the pack-
ing Worse the packing may be forced
to serve both as a bearing and a seal To
withstand these conditions the packing
should be resilient elastic and resistant
to deformation These properties rule
out packing such as graphite foil in favor
of fiber-based materials
Multi-Stage PumpsMulti-stage pumps are used for high-
pressure applications such as feeding
the boilers in steam-powered generating
plants Stuffing box pressure can vary
with pump design and number of stag-
es Designed for clean fluids and high
operating speeds these pumps typically
have high- and low-pressure ends with ahydraulic pressure equalization line run-
ning between the stuffing boxes
Like vertical pumps multi-stage
pumps feature a series of impellers to
build fluid discharge pressure In the
case of the six-stage pump pictured in
Figure 8 fluid enters at the drive end
where a stuffing box is exposed to suc-
tion pressure Channeled from one
impeller to the next through the pump
casting the fluid can reach extremely
high pressures at discharge
A second stuffing box located at the
bearing end is exposed to an intermedi-
ate pressure from the third impeller This
pressure is greater than the suction pres-
sure but much less than the discharge
pressure which can reach 2000 PSI
Fortunately the stuffing boxes in
these pumps are not exposed to dis-
charge pressures and typically see be-
low 500 PSI which is within the range
of some packing materials
wwwflowcontrolnetworkcom January 2015 29
Figure 5
Figure 6
Figure 7
Figure 8
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 33450 January 2015
Flow Control Magazine
| Gear PumpsPositive-displacement or gear pumps
operate on a different principle than
centrifugal pumps In external gear
pumps the fluid flows around the out-
side of the gears the intermeshing
of which forces it through the pump
to discharge (Figure 9) This design
makes these pumps particularly suit-
able for use with highly viscous fluids
such as resins emulsions syrups and
adhesives As such they are used for
transfer or metering applications
It should be noted gear pumps will
continue to displace fluid as long as
their shafts are turning which can pose
a problem if a clog occurs at the dis-
charge The resulting buildup of pres-
sure can blow out seals and damage
the pump Therefore most gear pumps
have pressure relief valves to divert
fluid back to the suction side for re-
circulation through the pump Internal
gear pumps operate slightly differently
but also have pressure relief valves to
prevent damage from excessive pres-
sure (Figure 10) In both external and
internal gear pumps the maximum
stuffing box pressure is determined by
these valves
Other rotating equipment includes
mixersagitators which are similar to
pumps in terms of the speeds to which
the packing is exposed There are ba-
sically three types of mixersagitators
top- bottom- and side-entry Top-entry
models are subject to the same con-
cerns about shaft run-out ldquowhiprdquo and
lateral forces on the paddles that are
encountered in some vertical pumps
Although some fluid may splash onto
the packing these mixers basically run
dry so the packing must have the abil-
ity to dissipate the resulting frictional
heat
In bottom-entry mixers the packing
is always exposed to fluid and may also
be exposed to solids requiring abra-
sion-resistance If the seal fails the en-
tire contents of the tank will eventually
drain out onto the bearings the floor
and other components under the stuff-
ing box
The packing in side-entry mixers may
be fully or intermittently exposed to flu-
id as well as side loading and vibration
Aside from media temperature
speed and other application variables
the configurations and operating prin-
ciples of rotary-type pumps exert differ-
ent forces on the seals used to keep
them from leaking These forces can
spell the difference between accept-
able seal performance and failure
Understanding these differences has
important implications that should be
taken into account to assure proper
sealing selection for long-term trou-
ble-free performance FC
wwwgarlockcom
Chris Boss is
a senior applica-
tions engineer for
Garlock Sealing
Technologies in
Palmyra NY He
has held various
positions in produc-
tion engineering
product development and applica-
tions engineering for the companyrsquos
compression packing division He
is a BSME graduate of the State
University of New York at Buffalo Mr
Boss can be reached at 800 448-
6688 or chrisbossgarlockcom
Chris Boss
Cavitation | Centrifugal Pump | Pump Packing | Sealing System
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Figure 9
Figure 10
Aside from media temperature speed and
other application variables the configurations
and operating principles of rotary-type
pumps exert different forces on the seals used
to keep them from leaking These forces can
spell the difference between acceptable seal
performance and failure
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3445
NS IDERNDUSTRIAL AUTOMATION + PROCESS CONTROL
WANT
INFORMATION
ON THE
automationindustry
SUBSCRIBE NOW at wwwiainsidercouk
Published by Spitzer and Boyes LLC Write in 15 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3545
Frost says the push from developing
economies is important as the market
is technologically mature and seeing
restricted growth in developed econo-
mies This is particularly true in Europe
and North America where recent finan-
cial insta-
bility has
reduced capital expenditure across end-
user industries
Bill Moore senior vice president of
sales development and channel man-
agement for global bearings manufac-
turer SKF says ldquosmartrdquo products and
the expansion of robust reliability pro-
grams are helping to drive new invest-
ment particularly in developed coun-
tries where the cost to compete is
high Frost says the magnitude of
the existing global installed base will
strengthen the need for replacement
and upgrades adding to market de-
mand as well
Frost says despite the potential
in developing economies the focus
on price as a product differentiator
may lead to intense price pressures
among manufacturers and bring down
the value of the overall market in the
short term The growing trend among
consumers to choose low-cost Chinese
imports will complicate this challenge
As price and quality become stan-
dardized across the globe customers
will base more of their purchasing deci-
sions on value-added services accord-
ing to Frost This will push manufactur-
ers to create more maintenance-free
solutions such as lubrication-free
bearings that offer end-users savings
on service and replacement costs and
reduce downtimeldquoOffering a complete line of prod-
ucts with comprehensive services will
be another feather in the cap of ven-
dors looking to widen their consumer
baserdquo notes Frost Industrial Automa-
tion and Process Control Research
Analyst Guru Mahesh
Moore says the trend of outsourcing
manufacturing to regions where labor
and production costs are favorable is
becoming less of a factor
ldquoThe days when cheap labor made
a significant difference in where a prod-
uct is manufactured mdash particularly high
value-added products or high weight
and bulk products mdash are coming to
an end as the cost of transportation
storage and inventory balance out the
benefits of production costs where la-
bor is a smaller percentage of the cost
of manufacturingrdquo Moore says ldquoLocal
manufacturing development will indeed
come to developing countries as their
ability to create markets that generate
economies of scale that support local
production is a clear trend and one that
all manufacturers will pay attention tordquo
Moore says that development of
maintenance-free or predictive tech-
nologies and products will be a sig-
nificant advantage to everyone in the
Bearing amp Coupling Manufacturers Focus
onDEVELOPING Economies
amp EFFICIENCY InnovationBy Amy W Richardson
2 January 2015
Flow Control Magazine
|
gy
Anew study from Frost amp Sullivan (wwwfrostcom) fore-
casts steady growth for the overall bearings and couplings
market based on rapid industrial development in high-growth
regions Specifically Frost predicts development in Mexico
Indonesia Nigeria Turkey Brazil Russia India and Chinawill help boost the bearings amp couplings market from $2206
billion in 2013 to an estimated $2676 billion in 2018
The development of maintenance-freeor predictive technologies will helpboost growth in the bearings market For example SKF is developing products that will automatically notifyusers when a bearing or mechanicalrotating component is approachingthe end of its useful life Pictured hereis an SKF Microlog analyzer a por- table condition monitoring tool
COURTESY SKF
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
improved productivity through simplified solutions The powerful technology and tools ensure repeatable
reliable accurate measurements Easier access to process data allows for better troubleshooting process
optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
For daily product notes visit the lsquoFeatured Productsrsquo section flowcontrolnetworkcom
ON THE WEB
1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3845
FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
and benefits as well as grids of
instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
services provided for the
mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
Brought to you by Beamex
Your Source For Fluid Handling Videos
Go towwwflowcontrolnetworkcomfreeinfo
Select appropriate issue ofFlow Control Magazine
Select advertisements thatinterest you
Enter your email amp clickldquoSubmit Requestrdquo
1
2
3
4
PRODUCT
INFORMATION
ONLINE
Follow these 4 steps to receive freeproduct information from suppliers
FREE
FEATURED VIDEO How to Calibrate aPressure Measurement Loop
For more information about FlowTube
sponsor packs email FlowControlGrandViewMediacom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4245
THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
Name ________________________________________________________________
Title _________________________________________________________________
Company _____________________________________________________________
AddressCityStateZip __________________________________________________
______________________________________________________________________
Phone ________________________________________________________________
E-Mail ________________________________________________________________
One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545
![Page 33: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/33.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 33450 January 2015
Flow Control Magazine
| Gear PumpsPositive-displacement or gear pumps
operate on a different principle than
centrifugal pumps In external gear
pumps the fluid flows around the out-
side of the gears the intermeshing
of which forces it through the pump
to discharge (Figure 9) This design
makes these pumps particularly suit-
able for use with highly viscous fluids
such as resins emulsions syrups and
adhesives As such they are used for
transfer or metering applications
It should be noted gear pumps will
continue to displace fluid as long as
their shafts are turning which can pose
a problem if a clog occurs at the dis-
charge The resulting buildup of pres-
sure can blow out seals and damage
the pump Therefore most gear pumps
have pressure relief valves to divert
fluid back to the suction side for re-
circulation through the pump Internal
gear pumps operate slightly differently
but also have pressure relief valves to
prevent damage from excessive pres-
sure (Figure 10) In both external and
internal gear pumps the maximum
stuffing box pressure is determined by
these valves
Other rotating equipment includes
mixersagitators which are similar to
pumps in terms of the speeds to which
the packing is exposed There are ba-
sically three types of mixersagitators
top- bottom- and side-entry Top-entry
models are subject to the same con-
cerns about shaft run-out ldquowhiprdquo and
lateral forces on the paddles that are
encountered in some vertical pumps
Although some fluid may splash onto
the packing these mixers basically run
dry so the packing must have the abil-
ity to dissipate the resulting frictional
heat
In bottom-entry mixers the packing
is always exposed to fluid and may also
be exposed to solids requiring abra-
sion-resistance If the seal fails the en-
tire contents of the tank will eventually
drain out onto the bearings the floor
and other components under the stuff-
ing box
The packing in side-entry mixers may
be fully or intermittently exposed to flu-
id as well as side loading and vibration
Aside from media temperature
speed and other application variables
the configurations and operating prin-
ciples of rotary-type pumps exert differ-
ent forces on the seals used to keep
them from leaking These forces can
spell the difference between accept-
able seal performance and failure
Understanding these differences has
important implications that should be
taken into account to assure proper
sealing selection for long-term trou-
ble-free performance FC
wwwgarlockcom
Chris Boss is
a senior applica-
tions engineer for
Garlock Sealing
Technologies in
Palmyra NY He
has held various
positions in produc-
tion engineering
product development and applica-
tions engineering for the companyrsquos
compression packing division He
is a BSME graduate of the State
University of New York at Buffalo Mr
Boss can be reached at 800 448-
6688 or chrisbossgarlockcom
Chris Boss
Cavitation | Centrifugal Pump | Pump Packing | Sealing System
Find related content flowcontrolnetworkcomhellipSearch onFLOWSTREAM
Figure 9
Figure 10
Aside from media temperature speed and
other application variables the configurations
and operating principles of rotary-type
pumps exert different forces on the seals used
to keep them from leaking These forces can
spell the difference between acceptable seal
performance and failure
ldquo
rdquo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3445
NS IDERNDUSTRIAL AUTOMATION + PROCESS CONTROL
WANT
INFORMATION
ON THE
automationindustry
SUBSCRIBE NOW at wwwiainsidercouk
Published by Spitzer and Boyes LLC Write in 15 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3545
Frost says the push from developing
economies is important as the market
is technologically mature and seeing
restricted growth in developed econo-
mies This is particularly true in Europe
and North America where recent finan-
cial insta-
bility has
reduced capital expenditure across end-
user industries
Bill Moore senior vice president of
sales development and channel man-
agement for global bearings manufac-
turer SKF says ldquosmartrdquo products and
the expansion of robust reliability pro-
grams are helping to drive new invest-
ment particularly in developed coun-
tries where the cost to compete is
high Frost says the magnitude of
the existing global installed base will
strengthen the need for replacement
and upgrades adding to market de-
mand as well
Frost says despite the potential
in developing economies the focus
on price as a product differentiator
may lead to intense price pressures
among manufacturers and bring down
the value of the overall market in the
short term The growing trend among
consumers to choose low-cost Chinese
imports will complicate this challenge
As price and quality become stan-
dardized across the globe customers
will base more of their purchasing deci-
sions on value-added services accord-
ing to Frost This will push manufactur-
ers to create more maintenance-free
solutions such as lubrication-free
bearings that offer end-users savings
on service and replacement costs and
reduce downtimeldquoOffering a complete line of prod-
ucts with comprehensive services will
be another feather in the cap of ven-
dors looking to widen their consumer
baserdquo notes Frost Industrial Automa-
tion and Process Control Research
Analyst Guru Mahesh
Moore says the trend of outsourcing
manufacturing to regions where labor
and production costs are favorable is
becoming less of a factor
ldquoThe days when cheap labor made
a significant difference in where a prod-
uct is manufactured mdash particularly high
value-added products or high weight
and bulk products mdash are coming to
an end as the cost of transportation
storage and inventory balance out the
benefits of production costs where la-
bor is a smaller percentage of the cost
of manufacturingrdquo Moore says ldquoLocal
manufacturing development will indeed
come to developing countries as their
ability to create markets that generate
economies of scale that support local
production is a clear trend and one that
all manufacturers will pay attention tordquo
Moore says that development of
maintenance-free or predictive tech-
nologies and products will be a sig-
nificant advantage to everyone in the
Bearing amp Coupling Manufacturers Focus
onDEVELOPING Economies
amp EFFICIENCY InnovationBy Amy W Richardson
2 January 2015
Flow Control Magazine
|
gy
Anew study from Frost amp Sullivan (wwwfrostcom) fore-
casts steady growth for the overall bearings and couplings
market based on rapid industrial development in high-growth
regions Specifically Frost predicts development in Mexico
Indonesia Nigeria Turkey Brazil Russia India and Chinawill help boost the bearings amp couplings market from $2206
billion in 2013 to an estimated $2676 billion in 2018
The development of maintenance-freeor predictive technologies will helpboost growth in the bearings market For example SKF is developing products that will automatically notifyusers when a bearing or mechanicalrotating component is approachingthe end of its useful life Pictured hereis an SKF Microlog analyzer a por- table condition monitoring tool
COURTESY SKF
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
improved productivity through simplified solutions The powerful technology and tools ensure repeatable
reliable accurate measurements Easier access to process data allows for better troubleshooting process
optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
For daily product notes visit the lsquoFeatured Productsrsquo section flowcontrolnetworkcom
ON THE WEB
1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3845
FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
and benefits as well as grids of
instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
services provided for the
mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
Brought to you by Beamex
Your Source For Fluid Handling Videos
Go towwwflowcontrolnetworkcomfreeinfo
Select appropriate issue ofFlow Control Magazine
Select advertisements thatinterest you
Enter your email amp clickldquoSubmit Requestrdquo
1
2
3
4
PRODUCT
INFORMATION
ONLINE
Follow these 4 steps to receive freeproduct information from suppliers
FREE
FEATURED VIDEO How to Calibrate aPressure Measurement Loop
For more information about FlowTube
sponsor packs email FlowControlGrandViewMediacom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4245
THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
Name ________________________________________________________________
Title _________________________________________________________________
Company _____________________________________________________________
AddressCityStateZip __________________________________________________
______________________________________________________________________
Phone ________________________________________________________________
E-Mail ________________________________________________________________
One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545
![Page 34: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/34.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3445
NS IDERNDUSTRIAL AUTOMATION + PROCESS CONTROL
WANT
INFORMATION
ON THE
automationindustry
SUBSCRIBE NOW at wwwiainsidercouk
Published by Spitzer and Boyes LLC Write in 15 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3545
Frost says the push from developing
economies is important as the market
is technologically mature and seeing
restricted growth in developed econo-
mies This is particularly true in Europe
and North America where recent finan-
cial insta-
bility has
reduced capital expenditure across end-
user industries
Bill Moore senior vice president of
sales development and channel man-
agement for global bearings manufac-
turer SKF says ldquosmartrdquo products and
the expansion of robust reliability pro-
grams are helping to drive new invest-
ment particularly in developed coun-
tries where the cost to compete is
high Frost says the magnitude of
the existing global installed base will
strengthen the need for replacement
and upgrades adding to market de-
mand as well
Frost says despite the potential
in developing economies the focus
on price as a product differentiator
may lead to intense price pressures
among manufacturers and bring down
the value of the overall market in the
short term The growing trend among
consumers to choose low-cost Chinese
imports will complicate this challenge
As price and quality become stan-
dardized across the globe customers
will base more of their purchasing deci-
sions on value-added services accord-
ing to Frost This will push manufactur-
ers to create more maintenance-free
solutions such as lubrication-free
bearings that offer end-users savings
on service and replacement costs and
reduce downtimeldquoOffering a complete line of prod-
ucts with comprehensive services will
be another feather in the cap of ven-
dors looking to widen their consumer
baserdquo notes Frost Industrial Automa-
tion and Process Control Research
Analyst Guru Mahesh
Moore says the trend of outsourcing
manufacturing to regions where labor
and production costs are favorable is
becoming less of a factor
ldquoThe days when cheap labor made
a significant difference in where a prod-
uct is manufactured mdash particularly high
value-added products or high weight
and bulk products mdash are coming to
an end as the cost of transportation
storage and inventory balance out the
benefits of production costs where la-
bor is a smaller percentage of the cost
of manufacturingrdquo Moore says ldquoLocal
manufacturing development will indeed
come to developing countries as their
ability to create markets that generate
economies of scale that support local
production is a clear trend and one that
all manufacturers will pay attention tordquo
Moore says that development of
maintenance-free or predictive tech-
nologies and products will be a sig-
nificant advantage to everyone in the
Bearing amp Coupling Manufacturers Focus
onDEVELOPING Economies
amp EFFICIENCY InnovationBy Amy W Richardson
2 January 2015
Flow Control Magazine
|
gy
Anew study from Frost amp Sullivan (wwwfrostcom) fore-
casts steady growth for the overall bearings and couplings
market based on rapid industrial development in high-growth
regions Specifically Frost predicts development in Mexico
Indonesia Nigeria Turkey Brazil Russia India and Chinawill help boost the bearings amp couplings market from $2206
billion in 2013 to an estimated $2676 billion in 2018
The development of maintenance-freeor predictive technologies will helpboost growth in the bearings market For example SKF is developing products that will automatically notifyusers when a bearing or mechanicalrotating component is approachingthe end of its useful life Pictured hereis an SKF Microlog analyzer a por- table condition monitoring tool
COURTESY SKF
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
improved productivity through simplified solutions The powerful technology and tools ensure repeatable
reliable accurate measurements Easier access to process data allows for better troubleshooting process
optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
For daily product notes visit the lsquoFeatured Productsrsquo section flowcontrolnetworkcom
ON THE WEB
1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3845
FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
and benefits as well as grids of
instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
services provided for the
mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
Brought to you by Beamex
Your Source For Fluid Handling Videos
Go towwwflowcontrolnetworkcomfreeinfo
Select appropriate issue ofFlow Control Magazine
Select advertisements thatinterest you
Enter your email amp clickldquoSubmit Requestrdquo
1
2
3
4
PRODUCT
INFORMATION
ONLINE
Follow these 4 steps to receive freeproduct information from suppliers
FREE
FEATURED VIDEO How to Calibrate aPressure Measurement Loop
For more information about FlowTube
sponsor packs email FlowControlGrandViewMediacom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4245
THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
Name ________________________________________________________________
Title _________________________________________________________________
Company _____________________________________________________________
AddressCityStateZip __________________________________________________
______________________________________________________________________
Phone ________________________________________________________________
E-Mail ________________________________________________________________
One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545
![Page 35: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/35.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3545
Frost says the push from developing
economies is important as the market
is technologically mature and seeing
restricted growth in developed econo-
mies This is particularly true in Europe
and North America where recent finan-
cial insta-
bility has
reduced capital expenditure across end-
user industries
Bill Moore senior vice president of
sales development and channel man-
agement for global bearings manufac-
turer SKF says ldquosmartrdquo products and
the expansion of robust reliability pro-
grams are helping to drive new invest-
ment particularly in developed coun-
tries where the cost to compete is
high Frost says the magnitude of
the existing global installed base will
strengthen the need for replacement
and upgrades adding to market de-
mand as well
Frost says despite the potential
in developing economies the focus
on price as a product differentiator
may lead to intense price pressures
among manufacturers and bring down
the value of the overall market in the
short term The growing trend among
consumers to choose low-cost Chinese
imports will complicate this challenge
As price and quality become stan-
dardized across the globe customers
will base more of their purchasing deci-
sions on value-added services accord-
ing to Frost This will push manufactur-
ers to create more maintenance-free
solutions such as lubrication-free
bearings that offer end-users savings
on service and replacement costs and
reduce downtimeldquoOffering a complete line of prod-
ucts with comprehensive services will
be another feather in the cap of ven-
dors looking to widen their consumer
baserdquo notes Frost Industrial Automa-
tion and Process Control Research
Analyst Guru Mahesh
Moore says the trend of outsourcing
manufacturing to regions where labor
and production costs are favorable is
becoming less of a factor
ldquoThe days when cheap labor made
a significant difference in where a prod-
uct is manufactured mdash particularly high
value-added products or high weight
and bulk products mdash are coming to
an end as the cost of transportation
storage and inventory balance out the
benefits of production costs where la-
bor is a smaller percentage of the cost
of manufacturingrdquo Moore says ldquoLocal
manufacturing development will indeed
come to developing countries as their
ability to create markets that generate
economies of scale that support local
production is a clear trend and one that
all manufacturers will pay attention tordquo
Moore says that development of
maintenance-free or predictive tech-
nologies and products will be a sig-
nificant advantage to everyone in the
Bearing amp Coupling Manufacturers Focus
onDEVELOPING Economies
amp EFFICIENCY InnovationBy Amy W Richardson
2 January 2015
Flow Control Magazine
|
gy
Anew study from Frost amp Sullivan (wwwfrostcom) fore-
casts steady growth for the overall bearings and couplings
market based on rapid industrial development in high-growth
regions Specifically Frost predicts development in Mexico
Indonesia Nigeria Turkey Brazil Russia India and Chinawill help boost the bearings amp couplings market from $2206
billion in 2013 to an estimated $2676 billion in 2018
The development of maintenance-freeor predictive technologies will helpboost growth in the bearings market For example SKF is developing products that will automatically notifyusers when a bearing or mechanicalrotating component is approachingthe end of its useful life Pictured hereis an SKF Microlog analyzer a por- table condition monitoring tool
COURTESY SKF
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
improved productivity through simplified solutions The powerful technology and tools ensure repeatable
reliable accurate measurements Easier access to process data allows for better troubleshooting process
optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
For daily product notes visit the lsquoFeatured Productsrsquo section flowcontrolnetworkcom
ON THE WEB
1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3845
FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
and benefits as well as grids of
instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
services provided for the
mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
Brought to you by Beamex
Your Source For Fluid Handling Videos
Go towwwflowcontrolnetworkcomfreeinfo
Select appropriate issue ofFlow Control Magazine
Select advertisements thatinterest you
Enter your email amp clickldquoSubmit Requestrdquo
1
2
3
4
PRODUCT
INFORMATION
ONLINE
Follow these 4 steps to receive freeproduct information from suppliers
FREE
FEATURED VIDEO How to Calibrate aPressure Measurement Loop
For more information about FlowTube
sponsor packs email FlowControlGrandViewMediacom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4245
THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
Name ________________________________________________________________
Title _________________________________________________________________
Company _____________________________________________________________
AddressCityStateZip __________________________________________________
______________________________________________________________________
Phone ________________________________________________________________
E-Mail ________________________________________________________________
One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545
![Page 36: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/36.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3645
production chain
ldquoIn a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products that
will not only help developing
countries but also help speed
replacement cycles in highly
developed countries with the
result being improved produc-
tivity and thus improved cus-
tomer profitabilityrdquo Moore says
ldquoAt SKF we are developing prod-
ucts that will automatically notify users
when a bearing or mechanical rotating
component is approaching the end ofits useful liferdquo Moore says ldquoIn addi-
tion we are developing products and
services that will help factory operators
predict failure and then identify the root
cause of the failure so that repair can
be done in a way that will significantly
increase the life of the asset that the
bearing gear or seal is supporting
Mahesh notes that fluctuating
currency exchange rates will also en-courage manufacturers to expand
geographically further extending their
reach to high-growth regions
While described as mature in terms
of technology suppliers believe there is
still space for technological
advances in the market to
help with the growth trend
Moore says the combination
of intelligent electronic tech-
nology with traditional me-
chanical technology is one
of the areas that will develop
quickly over the next decade
ldquoHigh investment and
operations cost sectors are
much more willing to look
at new technological innovations both
in products and services that will im-
prove productivity and reduce the cost
of downtimerdquo Moore saysFC
Amy W Richardson is the manag-
ing editor of Flow Control magazine
She can be reached at ARichardson
GrandViewMediacom
wwwflowcontrolnetworkcom January 2015 33
In a world where plant floor
and maintenance expertise will
be challenged we are develop-
ing easy-to-install products
that will not only help devel-oping countries but also help
speed replacement cycles in
highly developed countries
ldquo
rdquo
Do You
Know amp Understand Your PumpsLarry Bachus (The Pump Guy) is theco-author of Everything You Need to Know About Pumps one of the best selling 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 dustthis book gathers dirt smudges Its pages get creased 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 greaseand coffee Basically it gets used because its 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 at
wwwbachusinccombookshtml
Do You
Know amp Understand Your Pumps
Write in 16 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
improved productivity through simplified solutions The powerful technology and tools ensure repeatable
reliable accurate measurements Easier access to process data allows for better troubleshooting process
optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
For daily product notes visit the lsquoFeatured Productsrsquo section flowcontrolnetworkcom
ON THE WEB
1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3845
FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
and benefits as well as grids of
instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
services provided for the
mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
Brought to you by Beamex
Your Source For Fluid Handling Videos
Go towwwflowcontrolnetworkcomfreeinfo
Select appropriate issue ofFlow Control Magazine
Select advertisements thatinterest you
Enter your email amp clickldquoSubmit Requestrdquo
1
2
3
4
PRODUCT
INFORMATION
ONLINE
Follow these 4 steps to receive freeproduct information from suppliers
FREE
FEATURED VIDEO How to Calibrate aPressure Measurement Loop
For more information about FlowTube
sponsor packs email FlowControlGrandViewMediacom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4245
THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
Name ________________________________________________________________
Title _________________________________________________________________
Company _____________________________________________________________
AddressCityStateZip __________________________________________________
______________________________________________________________________
Phone ________________________________________________________________
E-Mail ________________________________________________________________
One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545
![Page 37: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/37.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 374534 | January 2015
Flow Control Magazine
P CLOSE | Flow Measurement ADVERTORIAL
Micro Motion Model 5700 Coriolis transmitter delivers the best in measurement technology and offers
unparalleled support mdash providing you with total measurement confidence valuable process insight and
improved productivity through simplified solutions The powerful technology and tools ensure repeatable
reliable accurate measurements Easier access to process data allows for better troubleshooting process
optimization and tighter control And the more intuitive
design and delivery means the product is easier to
use and support FREE INFO WRITE IN 100 |
wwwmicromotioncom5700
Next-Generation Coriolis Transmitterfor Greater Process Insight
For daily product notes visit the lsquoFeatured Productsrsquo section flowcontrolnetworkcom
ON THE WEB
1 Total Measurement Confidence The faster pro-cessing speed provides unmatched sensitivity to dynamic
flow conditions with better response and less noise Plusthe online diagnostics tool Smart Meter Verification pro- vides a quick and reliable indication of the meter health mdashfrom tube structure to electronics
2 Simplified Work Practices The intuitive transmitterinterface allows for easier navigation greater control andthe ability to configure the meter directly from the display And the new file shuttling capability allows you to configureand audit the meter from the safety and comfort of youroffice mdash reducing your time spent in the field
3 Unmatched System Connectivity Availability ofup to five fully configurable IO channels allows you to moni-
tor more process measurements from a single device Also you can purchase the transmitter integrally mounted to yoursensor or as a remote-mount transmitter which offers both4-wire and 9-wire connectivity
4 Powerful Tools For Greater Process Insight Actionable alerts provide guidance on operational issues mdash with
descriptive details about the alert and recommended actions
Detailed history files deliver key time-stamped information from
configuration changes and alerts to process events and statis-
tics for easier troubleshooting and process optimization
Key System Features
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3845
FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
and benefits as well as grids of
instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
services provided for the
mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
Brought to you by Beamex
Your Source For Fluid Handling Videos
Go towwwflowcontrolnetworkcomfreeinfo
Select appropriate issue ofFlow Control Magazine
Select advertisements thatinterest you
Enter your email amp clickldquoSubmit Requestrdquo
1
2
3
4
PRODUCT
INFORMATION
ONLINE
Follow these 4 steps to receive freeproduct information from suppliers
FREE
FEATURED VIDEO How to Calibrate aPressure Measurement Loop
For more information about FlowTube
sponsor packs email FlowControlGrandViewMediacom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4245
THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
Name ________________________________________________________________
Title _________________________________________________________________
Company _____________________________________________________________
AddressCityStateZip __________________________________________________
______________________________________________________________________
Phone ________________________________________________________________
E-Mail ________________________________________________________________
One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545
![Page 38: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/38.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 3845
FREE PRODUCT INFO For FREE PRODUCT INFO write in the numbers listed with each product in the FREE INFORMATIONsection on the reader service card bound in this issue of the magazine or visit wwwFlowControlNetworkcomfreeinfo
Liquid Level Detector
Automation Products Incrsquos Dynatrol CL-10GH Liq-
uid Level Detector has no floats diaphragms packingglands or moving parts The CL-10GH is designed for
more stability by utilizing the Dynatrol
EC-501A(G) control unit to eliminate
the variances of direct input power The
detector requires no field adjustments
and can be installed in almost any
position in a vessel
or pipe Specifi-
cations include
Explosion Proof CSA
NRTLC approvedfor Class 1 Group D
Division 1 Class 2 Groups E F and G Pressure Rat-
ing 3000 PSIG at 100 F Temperature Rating 300
F (high temperature construction available) Pressure
Connection 34rdquo NPT Conduit Connection 12rdquo NPT
Process Contact Surfaces 316 SS (standard)
wwwflowcontrolnetworkcom January 2015 | 35
FREE INFO WRITE IN 101 | wwwdynatrolusacom
NEW PRODUCTS
3rdquo Coriolis Flowmeter
TRICOR Coriolis Technology rsquos 3rdquo Coriolis flow-
meter in the TCM series is particularly suited to the
oil amp gas industry in applications such as measuring
the midstream transportation of oil amp gas rail car amp
truck loading allocation metering in crude oil and
natural gas production
and metering of refined
products in downstream
production applications Theflowmeter can measure flows
230000 kghr (8433 lbs
min) or 230000 lph (1012
gpm 34700 Bblday) and
withstand pressures up to
1450 PSI (100 bar) with a high
degree of accuracy (01 percent
of reading) Hazardous-area certifications include
ATEX Ex IIC T4 IECEx Zone 1 Group IIB T4 and
CSAcUS Class 1 Div 1
FREE INFO WRITE IN 104 | wwwtricorflowcom
Pneumatic Needle Valves
Clippardrsquos new GNV Series of miniature pneumatic
needle valves is available with 18rdquo 14rdquo and 38rdquo
port sizes with flow rates up to 60 scfm at 100 PSIG
Mounting options
include direct and
in-line as well as
cartridge styles Ad-
justment is achieved
by either a recessedslot or knurled
knob Needle valves
are used to control the rate of flow in a pneumatic
system by controlling flow in both directions Material
enters the input port travels through an adjustable
orifice and out the output port Clippardrsquos GNV Series
needle valves offer a rugged and compact design
provide bidirectional flow control multiple mounting
options 360-degree rotating parts and are suited for
use with Clippard push-quick fittings
FREE INFO WRITE IN 103 | wwwclippardcom
Peristaltic Pump Tube Assembly
Blue-Whitersquos Flex-A-Prene heavy-duty multi-chan-
nel pump tube assembly is designed exclusively forBlue-Whitersquos Flex-Pro and Proseries-M Peristaltic
Metering Pumps Flex-A-Prene is engineered and
designed for
optimum perfor-
mance and pres-
sure capability
up to 110 PSI
With tube life of
up to four times
longer than con-
ventional tubedesigns precise flow rate and excellent chemical
resistance this pump tube is designed to cut down
on pump maintenance and cost The clamp-less
tube fitting is available with multiple connection fit-
ting types including frac12rdquo MNPT barb fitting and 38rdquo
tube compression tri-clamp and quick disconnect
FREE INFO WRITE IN 102 | wwwblue-whitecom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
and benefits as well as grids of
instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
services provided for the
mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
Brought to you by Beamex
Your Source For Fluid Handling Videos
Go towwwflowcontrolnetworkcomfreeinfo
Select appropriate issue ofFlow Control Magazine
Select advertisements thatinterest you
Enter your email amp clickldquoSubmit Requestrdquo
1
2
3
4
PRODUCT
INFORMATION
ONLINE
Follow these 4 steps to receive freeproduct information from suppliers
FREE
FEATURED VIDEO How to Calibrate aPressure Measurement Loop
For more information about FlowTube
sponsor packs email FlowControlGrandViewMediacom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4245
THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
Name ________________________________________________________________
Title _________________________________________________________________
Company _____________________________________________________________
AddressCityStateZip __________________________________________________
______________________________________________________________________
Phone ________________________________________________________________
E-Mail ________________________________________________________________
One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545
![Page 39: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/39.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 394536 | January 2015 Flow Control Magazine
WEB RESOURCE FILE
wwwcmeflowcom
CMErsquos Smart Digital Flowmeters Equippedwith Easy-to-Read Digital DisplayCMErsquos Smart Digital
Flowmeters are a
combination of the
companyrsquos Laminar
Flow Elements and
its Flow Computers
Temperature abso-
lute pressure anddifferential-pressure transducers housed within the Flow
Computer monitor the conditions of the gas in the flow
stream as it flows through the Laminar Flow Element
CMErsquos digital flowmeters are also equipped with a large
easy-to-read digital display FREE INFO WRITE IN 202
wwwomegacomliterature Environmental-Monitoring
Environmental Monitoring CatalogNew Horizons in Environmental Monitoring is com-prised of more than 150 full-color
pages that feature the latest
environmental-related products
from Omega Engineering The
book is divided into the following
sections Temperature Heaters
Flow Level pH Conductivity amp
Laboratory Pressure and Data
Acquisition A user-friendly index is
available for easy product search
economical choices popular mod-
els and accessories FREE INFO WRITE IN 205
wwwjet-mpcombrochuresabb_randcpdf
Process amp Control Instruments BrochureABB Measurement Productsrsquo
has a new 24-page brochure
that details the companyrsquos
recording and controlling instru-
mentation Available as a PDF
download the brochure includes
photos of all devices along with
detailed descriptions of features
and benefits as well as grids of
instrument models versus gen-
eral capabilities inputsoutputs
advanced features communications and physical attri-
butes FREE INFO WRITE IN 200
wwwchemineercom
Mining amp Mineral Processing BrochureChemineerrsquos new bro-
chure describes the cus-
tomer benefits associated
with its heavy-duty mixing
products and its customer
services provided for the
mining industry The bro-
chure details manufacturing
capabilities available prod-ucts for minerals process-
ing and information about
Chemineer Express (after-
market sales and service)
facilities and services FREE INFO WRITE IN 203
wwwdwyer-instcomnewintl2015catalog
Instrumentation amp Control CatalogAppDwyer Instruments Incrsquos
free 2015 instrumentation
and controls catalog is now
available in print or digital
CD The CD offers interactive
features including keyword
search notes addition page
print and page save in PDF
Also available for download is
the 2015 Dwyer Catalog App
on the iOS and Google Play
markets for the iPad iPhone
or any Android mobile device You may now download the
entire catalog to view offline FREE INFO WRITE IN 204
wwwashcroftcom
Pressure amp Temperature WebsiteAshcroftrsquos newly enhanced website reflects the
instrument manufacturerrsquos
refreshed brand and image
and provides tools that
include a product selector
product part number con-
figurator material selector
and a wake frequency calcu-
lator Also new are industry-
specific guides to assist in
locating the most appropri-
ate instrument for customer
requirements FREE INFO
WRITE IN 201
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
Brought to you by Beamex
Your Source For Fluid Handling Videos
Go towwwflowcontrolnetworkcomfreeinfo
Select appropriate issue ofFlow Control Magazine
Select advertisements thatinterest you
Enter your email amp clickldquoSubmit Requestrdquo
1
2
3
4
PRODUCT
INFORMATION
ONLINE
Follow these 4 steps to receive freeproduct information from suppliers
FREE
FEATURED VIDEO How to Calibrate aPressure Measurement Loop
For more information about FlowTube
sponsor packs email FlowControlGrandViewMediacom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4245
THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
Name ________________________________________________________________
Title _________________________________________________________________
Company _____________________________________________________________
AddressCityStateZip __________________________________________________
______________________________________________________________________
Phone ________________________________________________________________
E-Mail ________________________________________________________________
One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545
![Page 40: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/40.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4045
A New Series of Six Studies from Flow Research - NOW AVAILABLE
A Six-Path Solution
to Oil Flow Research
CORE STUDY The World Market for Oil Flow Measurement
MODULE A Oil Producers Worldwide
MODULE B Oil Producers in the Middle East and Africa
MODULE C The World Market for Custody Transfer of Petroleum Liquids
MODULE D Strategies Industries and Applications
MODULE E The World Market for Multiphase Flowmeters
Order the entire set and receive a major discount plus additional benefits
We create change in flow
Flow Research Inc27 Water Street bull Wakefield MA 01880 USA(781) 245-3200 bull Fax (781) 224-7552wwwflowresearchcom bull wwwoilflowscominfoflowresearchcom
For more information contact
A
Oil ProducersWorldwide
B
Oil Producers inMideastAfrica
E
MultiphaseFlowmeters
D
Strategies Industriesamp Applications
C
CustodyTransfer
The World Marketfor Oil FlowMeasurement
CORE STUDY
Write in 17 or Request Info Instantly at wwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
flwctrlcom1uGdCSz
Brought to you by Beamex
Your Source For Fluid Handling Videos
Go towwwflowcontrolnetworkcomfreeinfo
Select appropriate issue ofFlow Control Magazine
Select advertisements thatinterest you
Enter your email amp clickldquoSubmit Requestrdquo
1
2
3
4
PRODUCT
INFORMATION
ONLINE
Follow these 4 steps to receive freeproduct information from suppliers
FREE
FEATURED VIDEO How to Calibrate aPressure Measurement Loop
For more information about FlowTube
sponsor packs email FlowControlGrandViewMediacom
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4245
THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
Name ________________________________________________________________
Title _________________________________________________________________
Company _____________________________________________________________
AddressCityStateZip __________________________________________________
______________________________________________________________________
Phone ________________________________________________________________
E-Mail ________________________________________________________________
One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545
![Page 41: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/41.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 414538 | January 2015 Flow Control Magazine
Find company websites and get free product information online at wwwflowcontrolnetworkcomfreeinfo
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
ASCO 13 22
Bachus Inc 33 NA
Badger Meter 15 11
CheckAll Valve 4 4
CME Aerospace ControlProducts
40 36 18 202
Collins Instrument Co 11 9
Eldridge Products BC 20
Emerson ProcessManagement ndash MicroMotion
34 100
Endress + Hauser 7 7
DVERTISERPRODUCT INDEX
Advertiser Page RS
Flexim Americas Corp 12 21
Flow Research Inc 37 17
FMC Technologies 5 6
Hoffer Flow Control IBC 19
KROHNE Inc 1 2
John C Ernst Company 4 5
Magnetrol International 3 3
NOSHOK 10 23
Omega Engineering Inc 17 12
Plast-o-Matic Inc 14 10
The Pump Guy 21 NA
Rosedale Products Inc 33 16
Sage Metering 9 8
Spitzer amp Boyes LLC 31 15
Viega LLC IFC 1
Product Page RS
Automation Products Inc 35 101
Blue-White Industries 35 102
Clippard 35 103
TRICOR Coriolis Technology 35 104
Advertiser Page RS Advertiser Page RS
Learn how to calibrate
a pressure mea-surement loopcontaining a pres-sure transmitterand control roomdisplay usingBeamex MC6 calibrator and BeamexPGM pressure pump
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Brought to you by Beamex
Your Source For Fluid Handling Videos
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7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4245
THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
Name ________________________________________________________________
Title _________________________________________________________________
Company _____________________________________________________________
AddressCityStateZip __________________________________________________
______________________________________________________________________
Phone ________________________________________________________________
E-Mail ________________________________________________________________
One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545
![Page 42: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/42.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4245
THINK TANK | Temperature Measuremen
ABSOLUTE ZERO Temperature at which thermal energyis equal to zero Defined as zero Kelvin calculated to be-27315 C or -45967 F
AMBIENT TEMPERATURE The temperature of the envi-ronment surrounding a particular location
CHARACTERIZATION The ability of a smart transmitterto compensate for ambient temperature changes non-linear-ities and other outside influences
COMPRESSIBILITY The ability of a substance to expandor contract in volume when acted upon by either tempera-ture or pressure Liquids are normally considered non-com-pressible by pressure They expand and contract to a limiteddegree in volume depending on their temperature Gases arecompressible and their volume is greatly affected by changesin pressure and temperature
CONDENSATE Distillate just after it has been cooledfrom steam into the liquid state
DROOP A common occurrence in time-proportional control-lers It refers to the difference in temperature between the setpoint and where the system temperature actually stabilizesdue to the time-proportioning action of the controller
DRT Digital Reference Thermometer (pronounced as DART)used to monitor temperature of media after holding tube inaseptic or HTST pasteurizer system
MELTING POINT The temperature at which a substancetransforms from a solid phase to a liquid phase
OVERSHOOT The number of degrees by which a processexceeds the set-point temperature when rising up to the set-point temperature
RTD Abbreviation for resistance temperature device Atemperature-sensing device that provides temperature infor-mation as the change in resistance of a metal wire elementoften platinum as a function of temperature
RTD TRANSMITTER A device that converts resistance valuefrom an RTD to a standard instrument signal (such as 4-20 mA)that can be communicated within a measurement control loop
THERMAL GRADIENT The distribution of a differentialtemperature through a body or across a surface
THERMISTOR A temperature-measuring device similarto a resistance temperature detector made of heat-treatedmetallic oxide
THERMOCOUPLE A temperature-sensing device com-posed of dissimilar thermoelectrically homogeneous wires joined at one end to form a measuring junction From athermocouple a voltage or EMF (electromotive force) is pro-duced if a temperature gradient exists between the measur-ing junction and the reference junction
UNDERSHOOT The difference in temperature between theset-point temperature and the temperature a process goes tobelow the set point after the cooling cycle is turned off
Source Endress+Hauser industrial measurement instrumen-tation services and solutions provider (wwwusendresscom)
GLOSSARY OF TERMS
TEMPERATURE MEASUREMENT
wwwflowcontrolnetworkcom January 2015 | 39
E C A A C H A R A C T E R I Z A T I O N
C T D R O O P S M I L T I N G P O I N T
R O A O R E Z E T U L O S B A T S T E T
T E N S U E L E N T R O E A T O O H R O
D R T D N T L D O O P H E C H O O T U U
M E A S E E D P O I P S O T S Z Y T T L
A T R T I N D T U O E R E R T T I N A E
T T N R D M S N U O T E E E I O I E R T
Z I R Z D L R A O T C V T L O O O I E E
E M D D S R I E T O O O I O P S B D P M
T S E I C M T S H E C B M G E D S A M R
U N D E R S H O O T I O N R E N A R E R
L A R T D T R A N S M I T T E R L G T N
O R C O N D E N S A T E D E T H O L T Z
S T E T R D E E G L U E I I T P T A N M
B D E R T I R E E A P E P R T N I M E C
A R E O I P I M E M A D N R R E Z R I G
T H E R M A C O U P L E R T L O E E B S
S E R O T S I M R E H T S D E M R H M V
L N C A R T E E H H E S N M T T O T A R
ABSOLUTE ZERO
AMBIENT TEMPERATURE
CHARACTERIZATION
COMPRESSIBILITY
CONDENSATE
DROOP
DRT
MELTING POINT
OVERSHOOT
RTD
RTD TRANSMITTER
THERMAL GRADIENT
THERMISTOR
THERMOCOUPLE
UNDERSHOOT
I would like to receivecontinue Flow Control magazine ____ Yes ____ No
Signature _____________________________________ Date _________________
Name ________________________________________________________________
Title _________________________________________________________________
Company _____________________________________________________________
AddressCityStateZip __________________________________________________
______________________________________________________________________
Phone ________________________________________________________________
E-Mail ________________________________________________________________
One lucky entrant who has solved the puzzle correctly will win a $50 Best Buygift card Best Buy is North Americarsquos leading consumer electronics retailer You can use your gift card in the store or online at wwwBestBuycom
Fax solution to (205) 408-3799If there are no completely correct entries a winner will be selectedfrom among the entries with the most words found
Solve This Word Search
Win a $50 Best Buy Gift Card
October Winner Karl Weidner Process Consultant
PLC Inc Louisville Ky
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545
![Page 43: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/43.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4345
HINK TANK | Flow Measurement
quiz corner How to Calculate Orifice Plate Flow Rate
40 | January 2015
Flow Control Magazine
Commentary The differential pressure developed across an orifice plate is
proportional to the square of the flow Therefore one-third
flow will generate one-ninth of the differential
Conversely the flow through an orifice plate is propor-
tional to the square root of the differential pressure devel-
oped In this case 10 percent of the differential pressure isdeveloped (1001000) so the flow rate can be calculated
as the square root of 010 or approximately 316 percent
of full scale flow
Answer C is closest to the calculated flow rate
Additional Complicating Factors This calculation assumes that the orifice flowmeter is
designed installed calibrated and operated correctly This
is not necessarily the case especially in gas applications
where the gas density is affected by varying operating condi-
tions such as pressure temperature and composition FC
wwwspitzerandboyescom
R R R F E L C E L L M L I F N I H T G C
T B R E N E W A B L E R E S O U R C E R
O C O M B I N E D C O L L E C T O R L E
Y R R E R T S O L A R E N E R G Y L S A
L L E W N O I T C E J N I M E T S A P E
Z L I F N I H T E Z I R O P A V Y M H D
S A L P H A T O V O L T A I C M R R O M
R T U Y G R E N E R E L O S S M E E T T
O B E I R R A D I A N C E Y E E N H O Y
T C L A A S S A D D H L U T O O E T V F
C L E L M E S I T L U E S S I C R O O G
U E Z C M I T O E F C Y F T T E A R L O
D U I S L C E C L N S N A U D L L D T E
N F R T E T L I A D R R W F E E O Y A E
O L A E S E S E I O E C S A S L S H I L
C I P N U S D R P N S C L D M E C F C L
I S A F O A B A E R M C D T E C L E U F
M S V F R Y V G H S E L I F N I H T L E
E O O R H L O H H N A T U R A L G A S L
S F I I E C E A C D I U T L E C A O I B
Div of AerospaceControlProducts Inc1314West 76th StreetDavenport IA 52806bull FAX 563-391-9231
E-mail address infocmeflowcom
The originators of gas laminar flowmeters
GAS FLOWACCURACY ASSURED with Model 60B Flow Computer
Model 60B Flow Computer
The 60B Flow Computers con-stantly process pressure temperature andflow data from a Laminar Flow Element (LFE)with a resulting accurate (plusmn 75 of point-NIST traceable) display of Standard (Mass)and Volumetric flowTotalizers and optionaloutputs are available
Save downtime and money with the FCS 9003 portable Flow Calibrator It utilizesa custom Windowstrade 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
Laminar Flow Elements bull MassVolumetric Digital Flowmeters bull Custom Test
Stands bull Analog Flowmeters bull Digital Manometers amp Altimeters
Call Rich Kennedy 800-845-0927
Seeus atwwwcmeflowcom
FCS-9003 Portable Calibrator
Write in 18 or Request Info Instantly at wwwFlowControlNetworkcom
November Solution Renewable Energy
An orifice plate is designed to generate a differential pres-sure of 1000 mm of water column at a full scale flow rate
of 100 liters per minute What is the approximate flow rate
when the orifice plate generates 100 mm of water column
A 10 percent of full scale flow B 25 percent of full scale flow
C 33 percent of full scale flow
D 50 percent of full scale flow
E None of the above
David W Spitzer is a regular contributor to Flow
Control magazine and a principal in Spitzer and BoyesLLC offering engineering seminars strategic marketing
consulting distribution consulting and expert witness
services for manufacturing and automation companies
Spitzer and Boyes is also the publisher of the Industrial
Automation Insider Spitzer has more than 35 years of
experience and has written over 10 books and 300 articles
about flow measurement instrumentation and process
control He can be reached at 845 623-1830 or www
spitzerandboyescom Click on the ldquoProductsrdquo tab to find
his Consumer Guides to various flow and level measure-
ment technologies
By David W Spitzer
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545
![Page 44: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/44.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4445
On-spec Not off-the-shelf
While some flowmeter companies offer off-the-shelf solutions that may or may not work for you Hoffer Flow Controls engineers and builds
flowmeters for your specific purpose regardless of what that purpose requires We meet the critical demands of even the most challenging applications
And we know that the best flowmetering system is often the solution designed specifically for it Regardless of your application you can count on Hoffer
to engineer a precisely accurate reliable easy-to-implement flowmetering system Purpose-built No matter what your purpose
800-628-4584 bull wwwhofferowcom
Purpose-Builttrade
Write in 19 or Request Info Instantly atwwwFlowControlNetworkcomfreeinfo
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545
![Page 45: Flow Control January 2015](https://reader030.vdocuments.site/reader030/viewer/2022021121/563db8cb550346aa9a970042/html5/thumbnails/45.jpg)
7232019 Flow Control January 2015
httpslidepdfcomreaderfullflow-control-january-2015 4545