flow control january 2015

45
JANUARY 2015 Vol. XXI, No. 1 www.FlowControlNetwork.com SOLUTIONS fo r FLUID MOVEMENT , MEASUREMENT & CONTAINMENT special section | pg 23 PUMPS, BEARINGS AND SEALS TECHNOLOGY REPORT  API 624 Valve Emissions STANDARD Update Considering K-FACTOR  ADJUSTMENTS How to CALCULATE Orice-Plate FLOW RATE 1  9  9 5    2 0   1    5 1  9  9 5    2 0   1    5 2 0th 2 0th

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Page 1: Flow Control January 2015

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

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Industrial press fitting solutionsfor clean controlled installations

Do more with Viega press fitting solutions

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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

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

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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

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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

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-

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of aggressive media

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THE OUTLOOK | News amp Notes

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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

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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

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FPD3300 SeriesStarts at

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Positive Displacement Flow Meterfor Fuels and Oils

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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

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

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

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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-

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

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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 3: Flow Control January 2015

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

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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

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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Temperature Measurement Solutions

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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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Monitor your Total Acid Consumption

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Contact us for a free trial measurement

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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

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range of easily configured features and options includes superior temperature and

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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

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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

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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

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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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

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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 __________________________________________________

______________________________________________________________________

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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 4: Flow Control January 2015

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

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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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THE OUTLOOK | News amp Notes

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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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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-

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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

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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 _________________

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

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

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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

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 6: Flow Control January 2015

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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THE OUTLOOK | News amp Notes

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httpslidepdfcomreaderfullflow-control-january-2015 1645

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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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David W Spitzer

Ammonia Gas | Coriolis Flowmeter | David W Spitzer | Scram | Troubleshooting

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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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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

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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

Connection (Availableon 1 and Larger Sizes)

Positive DisplacementFlow Meter for Solvents

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 7: Flow Control January 2015

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

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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

Warranties

Temperature Measurement Solutions

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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

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

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

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7232019 Flow Control January 2015

httpslidepdfcomreaderfullflow-control-january-2015 4545

Page 8: Flow Control January 2015

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

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

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THE OUTLOOK | News amp Notes

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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

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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

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FPD3300 SeriesStarts at

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Positive Displacement Flow Meterfor Fuels and Oils

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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 9: Flow Control January 2015

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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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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Monitor your Total Acid Consumption

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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

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range of easily configured features and options includes superior temperature and

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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

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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

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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

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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

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 10: Flow Control January 2015

7232019 Flow Control January 2015

httpslidepdfcomreaderfullflow-control-january-2015 1045

Endress+Hauser Inc

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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

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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

3

4

PRODUCT

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ONLINE

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FREE

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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 _________________

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

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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

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

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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

everything you expect any valve positioner to do

plus more The SRDrsquos comprehensive diagnostics tool

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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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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

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 12: Flow Control January 2015

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

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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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Positive Displacement Flow Meterfor Fuels and Oils

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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 13: Flow Control January 2015

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

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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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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-

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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

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

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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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

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bull Wide range of pressuresettings

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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

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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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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Positive Displacement Flow Meterfor Fuels and Oils

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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

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

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-

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advanced features communications and physical attri-

butes FREE INFO WRITE IN 200

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Mining amp Mineral Processing BrochureChemineerrsquos new bro-

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with its heavy-duty mixing

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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-

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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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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

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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 16: Flow Control January 2015

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

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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

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

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

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

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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

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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

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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

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Purpose-Builttrade

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7232019 Flow Control January 2015

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Page 17: Flow Control January 2015

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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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

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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

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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

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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

Connection (Availableon 1 and Larger Sizes)

Positive DisplacementFlow Meter for Solvents

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 18: Flow Control January 2015

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

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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

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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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

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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

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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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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

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Solve This Word Search

Win a $50 Best Buy Gift Card

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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

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7232019 Flow Control January 2015

httpslidepdfcomreaderfullflow-control-january-2015 4545

Page 19: Flow Control January 2015

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

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

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

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7232019 Flow Control January 2015

httpslidepdfcomreaderfullflow-control-january-2015 4545

Page 20: Flow Control January 2015

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

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Positive Displacement Flow Meterfor Fuels and Oils

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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

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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 _____________________________________________________________

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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

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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 21: Flow Control January 2015

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 22: Flow Control January 2015

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

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

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Page 23: Flow Control January 2015

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

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Page 24: Flow Control January 2015

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

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Page 25: Flow Control January 2015

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

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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 26: Flow Control January 2015

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

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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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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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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

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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

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that details the companyrsquos

recording and controlling instru-

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download the brochure includes

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advanced features communications and physical attri-

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wwwchemineercom

Mining amp Mineral Processing BrochureChemineerrsquos new bro-

chure describes the cus-

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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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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

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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

INFORMATION

ONLINE

Follow these 4 steps to receive freeproduct information from suppliers

FREE

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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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

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

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CORE STUDY The World Market for Oil Flow Measurement

MODULE A Oil Producers Worldwide

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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

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Oil ProducersWorldwide

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MultiphaseFlowmeters

D

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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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Select appropriate issue ofFlow Control Magazine

Select advertisements thatinterest you

Enter your email amp clickldquoSubmit Requestrdquo

1

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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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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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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

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

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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

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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

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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

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Purpose-Builttrade

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7232019 Flow Control January 2015

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Page 29: Flow Control January 2015

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 ________________________________________________________________

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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

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

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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

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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

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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

httpslidepdfcomreaderfullflow-control-january-2015 4545

Page 31: Flow Control January 2015

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-

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

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CORE STUDY The World Market for Oil Flow Measurement

MODULE A Oil Producers Worldwide

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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

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Oil ProducersWorldwide

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E

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D

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C

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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

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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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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

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Win a $50 Best Buy Gift Card

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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

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Call Rich Kennedy 800-845-0927

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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

httpslidepdfcomreaderfullflow-control-january-2015 4545

Page 32: Flow Control January 2015

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-

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download the brochure includes

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detailed descriptions of features

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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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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

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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

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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

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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 _________________

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

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

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

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

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

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

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

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

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

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 42: Flow Control January 2015

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

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

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

7232019 Flow Control January 2015

httpslidepdfcomreaderfullflow-control-january-2015 4545