User Appl i cat ion Guide

The mass flow experts for flow, level

and temperature instrumentation

Water and Wastewater Industry

YEARSOF

SERVICE

40

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

demands for the Water and Wastewater Industry. By utilizingThermal Dispersion and Coriolis technology exclusively in all FCIflow, level, interface, temperature switches and mass flow meters,our products solve typical Water and Wastewater Industry applicationchallenges with standard product features such as: No moving parts All welded materials of construction Direct mass flow measurement No pressure drop Explosion-proof design Wide flow range Low flow capability

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

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

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

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

interface detection

FCI Water and Wastewater Industry customers F. Wayne Hill Water Resources Center, Gwinnett County, GA Green Bay Metropolitan Sewerage District, Green Bay, WI East Bay Municipal Wastewater Treatment Plant, Oakland, CA Käppala Wastewater Treatment Plant, Stockholm, Sweden Ulu Pandan Wastewater Reclamation Plant, Singapore Alexandria Sanitation Authority Advanced WWT Facility

Alexandria, VA City of Las Vegas Northwest Water Resource Center, Las Vegas, NV City of Dayton Wastewater Treatment Plant, Dayton, OH City of Orlando Wastewater Treatment Plant, Orlando, FL NY DEP, Queens, NY

FCI Water and Wastewater Industry customers forEngineering, Procurement & Construction (EPC) CH2M Hill Black & Veatch Environmental Hazen & Sawyer Camp Dresser McKee Metcalf & Eddy Montgomery Watson Parsons Malcom Pirnie Brown & Caldwell Jacobs Engineering

Digester gas flow monitoring

The flow measurement of digester gas is critical to waste watertreatment plant operations. Typical plants have multiple digestersthat need constant monitoring. FCI’s ST98 FlexMASSter® Seriesmass flow meter provides extremely low flow sensitivity and wideturndown range. The no moving parts design is unaffected by thisdirty, humid gas.

Solv ing cr i t i ca l process appl i cat ions for the Water and Wastewater Industry

Flocculant/sludge control

Many sludge clarifiers separate solids from the effluent system byintroducing air and flocculants, so that sludge rises to the top thevessel and spills over a weir. The amount of air and flocculant arecontrolled by the level of the interface between the sludge andwater. Optical detectors, as interface sensors, have not been suc-cessful in this application because the sensors fail due to fouling.FCI’s FLT93S FlexSwitch® Series multipoint assembly identifies thechanging level of the sludge interface to enable control of flocculantand air addition.

Oxygen/ozone flowmetering

Advanced water treatment plants are using ozone and activated carbonfilters to reduce chlorine requirements in order to improve thetaste and appearance of the water they produce. On-site generationof ozone can become a significant operating expense; thereby makingits measurement and control an important requirement to efficientoperation of the plant. Ozone flow needs to be introduced into thefiltration process at three different points: For coagulation prior toprimary filtration, for low flow as an oxidizing agent, and for highflow disinfecting to breakdown pesticides. FCI’s ST98L FlexMASSterinline mass flow meters are installed at each point to measure theozone flow. The ST98L has the dynamic flow range and accuratesensitivity required for ozone applications.

Chlorine gas flow monitoring

Municipal water districts and waste water treatment facilities usechlorine to disinfect water. Proper, real-time control of chlorinedosage is critical to ensure smooth operation. FCI’s ST98 FlexMASSterSeries mass flow meters with a Hastelloy C-276 flow elementinstalled directly in the chlorine line ensures this critical flow. It isspecifically calibrated to anticipate chlorine demand based on watertemperature, flow rates, time of year and residual chlorine levels.

Reverse flow detection

Large water storage reservoirs are often filled and drained throughthe same water line. Federal and state requirements mandate thatall water delivered for human consumption be disinfected. In orderto minimize disinfectant usage, avoid overdosing and forgo disin-fecting water going into the reservoir, it is critical for water plantoperators to know the direction of water flows within the pipe lines.The use of FCI’s RF83 bi-directional flow monitor detects instantaneousflow direction, providing improved disinfectant control.

Chemical injection/additive flow monitoring

In monitoring chemical and other additive injection flow, the ultra-sensitive FLT93L inline FlexSwitch outperforms the competition. Itdetects gas flows down to 0.6 cc/sec and liquid flows down to 0.02cc/sec -- ideal for virtually all injection processes. The no-moving-parts flow element design provides outstanding durability and reli-ability under the harshest process conditions. And, the inherentthermal time-delay, available in all FCI flow switch /monitors, preventsfalse alarms caused by flow pulsation and eliminates the need forauxiliary time-delay relays. Optional dual switch point circuitryhelps maintain product quality and process safety by alarming bothhigh flow and low flow conditions.

Sample flow and gas chromatography

FCI inline flow switch /monitors are an integral part of samplingequipment ranging from ultra-sensitive gas chromatographs tolarge fluid sampling systems used to test for toxic agents in wastewatereffluent. Highly repeatable, with low flow sensitivity, FCI flowswitches ensure that sample rates will be maintained at the rightflow for accurate analysis. In systems where several products aretested individually by the same analyzer, each sample line is monitoredto verify that products are flowing one at a time. The FR73 inline ultralow flow monitor is especially well suited for gas chromatographs;while the FLT93S FlexSwitch Series and FR78 inline low flow monitorare recommended for larger analyzers.

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

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

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

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

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

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

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

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

continued on back cover

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

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

HeatedSensor

UnheatedSensor

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

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

Doc. No. 07SA011395A

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

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

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

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

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

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

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

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

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

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

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

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