Professional Documents
Culture Documents
Pr e dic t ive Ma in te n an c e
Facing
Production LOSSES
Printers Turn to a
july 2009
Vol. XV, No. 7
features
14 Spilled Ink new flowmeter makes its mark
on the printing industry
14
A new piston-based flowmeter design is attracting attention from several large printing companies that have been
struggling with the accuracy and reliability of their ink
metering systems.
columns
4
28
Effective airflow troubleshooting strategies can help ensure
that small process problems dont become big ones.
pumping systems
departments
6
products
26 FOCUS ON: Seals & Gaskets >>>>>
38 NEW PRODUCTS
34
The Pump Guy explains why the condition of static head
isnt an issue for the majority of the worlds pumps, i.e.
because most pumps operate in loop-based systems.
Flow Control (ISSN #1081-7107) is published 12 times a year by Grand View Media Group,
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2 July 2009
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Entire contents copyright 2009. No portion of this publication may be reproduced in any form
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Views expressed by the bylined contributors should not be construed as reflecting the opinion of this
publication. Publication of product/service information should not be deemed as a recommendation by
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details. Product/service information should be submitted in accordance with guidelines available from
the editor. Editorial closing date is two months prior to the month of publication. Advertising close is the
last working day of the month, two months prior to the month of publication.
Flow Control
FlowTechnology
World Class Flow Solutions
ftimeters.com/video/Geckodemo
ftimarket@ftimeters.com
Correct solutions entered into monthly prize
drawing. Solution posted on website.
1-866-910-FLOW
www.ftimeters.com
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viewpoint
4 July 2009
GV
G R A N D
V I E W
M E D I A
G R O U P
PUBLISHER
JOHN P. HARRIS
(205) 408-3765
john@grandviewmedia.com
ASSOCIATE PUBLISHER
KEVIN J. McCARTHY
(815) 873-1701
kevin@grandviewmedia.com
EDITOR
MATT MIGLIORE
(610) 828-1711
matt@grandviewmedia.com
COPYEDITOR
SCOTT NESMITH
COLUMNISTS
LARRY BACHUS;
DAVID W. SPITZER; JESSE YODER
Here Ive provided four open-ended questions about digital information delivery, which
Im hoping youll take a moment out of your
busy schedule to respond to. E-mail your
responses directly to me at matt@grandview
media.com. As an incentive, we will enter each
person that responds to this editorial into a random drawing for a $100 Best Buy gift card.
Thanks in advance for your feedback.
Administrative Team
1. In what format do you currently consume
the majority of your technical information
print or online? Do you see yourself changing
formats in the next 2-5 years?
2. What is the most bothersome thing about
the digital delivery of technical/engineering
information? Is there anything in particular
that bothers you about the way technical information is provided in a digital format?
3. What is the most beneficial thing about the
digital delivery of technical/engineering information? Are there any specific capabilities
that a digital environment offers that you find
particularly useful and/or enjoyable?
4. Going forward, what would you like to see
in the area of digital delivery of technical/engineering information that you have not
yet seen? If you were publisher of Flow
Control, what would be the first online project
you would launch for readers? FC
GENERAL MANAGER
BARRY LOVETTE
VICE PRESIDENT OF OPERATIONS
BRENT KIZZIRE
VICE PRESIDENT OF MARKETING
HANK BROWN
DIRECTOR OF CIRCULATION & FULFILLMENT
DELICIA POOLE
VICE PRESIDENT OF FINANCE
BRAD YOUNGBLOOD
WINNER
WINNER
WINNER
Maintenance Matters
Evolving from Preventive to Predictive Technology
by Matt Migliore
Types of Maintenance
To fully understand the value of predictive maintenance for certain applications, users must first grasp how maintenance procedures are classified and how they differ from each other. In
general terms, maintenance can be classified into three different
categories: corrective maintenance, preventive maintenance,
and predictive maintenance.
Corrective maintenance is generally characterized by a system that is run to failure before it is taken off line for maintenance. This form of maintenance, sometimes referred to as
repair maintenance, is the most inefficient method of maintaining systems. It generally results in unplanned downtime for
the process and requires the system to be pulled out of service
without prior preparation or planning. Very few modern-day
processes would be able to survive if operated on a corrective
maintenance program. Further, depending on the process conditions of the application, a corrective maintenance program may
compromise the safety of plant personnel and the environment.
Preventive maintenance has been, and remains, standard
practice for many fluid handling systems. Preventive maintenance, in general terms, is any time- or count-based maintenance procedure. The aim of a preventive maintenance program
is to maintain the operation of equipment without incurring
unplanned downtime. Preventive maintenance activities may
include tests, measurements, adjustments, and/or parts replacements all of which would be performed on a scheduled
and/or planned basis in an effort to ensure the operation of the
process without unplanned downtime. While a more effective
approach than corrective maintenance, the key limitation of preventive maintenance is that it occasionally results in maintenance being performed on systems that may not actually
require maintenance. Thus, preventive maintenance can be labor
intensive, ineffective in identifying problems that develop
between scheduled inspections, and costly.
Predictive maintenance is a data-based method of maintaining the operation of systems. So, instead of waiting for a system to fail or performing maintenance procedures on a timebased interval, predictive maintenance programs use key pieces
of process information in an effort to more precisely determine
6
July 2009
Preventive maintenance includes periodic removal, cleaning and lubrication of transducers on a pipe. Here an ultrasonic flowmeter features
transducers that can be changed on the fly without having to break
the line, minimizing downtime and maintenance requirements. Photo
courtesy of Thermo Fisher Scientific (www.thermo.com).
www.FlowControlNetwork.com
July 2009 7
July 2009
Flow Control
www.FlowControlNetwork.com
July 2009 9
10
July 2009
Flow Control
industry news
at Endress+Hauser as our crown jewel of
industry, said Henderson.
Endress+Hauser, which is a familyowned business, moved its U.S. operations from Beverly, Mass. to Greenwood,
Ind. in 1974. At that time, the U.S. operation employed only a handful of people.
There are now more than 300 employees
working at Endress+Hausers
Greenwood, Ind. campus, with more
than 50 jobs added in the last three years.
To view an online tour of the E+H magmeter calibration facility, visit
www.us.endress.com
www.FlowControlNetwork.com
July 2009 11
applications corner
by David W. Spitzer
www.spitzerandboyes.com
Industrial Flow
Measurement Seminar
Sept 22-24, 2009 - St. Louis, MO
David W. Spitzer, P.E., is bringing his highly regarded
three-day Industrial Flow Measurement Seminar to
St. Louis, MO. This exclusive training event is designed
for individuals who desire to become more productive
through improvement of their flow measurement skills.
For more information and to register, visit :
www.spitzerandboyes.com/seminar/semifm.htm.
Flow Control
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GdhZbdjci VcY i]Z GdhZbdjci ad\dineZ VgZ gZ\^hiZgZY igVYZbVg`h d[ GdhZbdjci! >cX#
technology spotlight
by Matt Migliore
Spilled Ink
New Metering System Makes Its Mark on the Printing Industry
Given the details of the application outlined here, one might wonder how the printer in question could have possibly operated for
so long with an ink meter that was performing so poorly. The
answer to this question can be traced back to the late 1980s. At
this time, viscosity wasnt a big issue for ink flow measurement, as
printing presses were fed ink from 47-gallon drums, and each
press had a dedicated pump. In this environment, the key characteristic printers were looking for in a meter was the capability to
reliably flow ink without clogging. For many printers, if the meter
could flow ink effectively, that was enough. The issue of inaccurate
flow measurement only arose when the printer continued on with
the same technology despite drastically changing application characteristics.
By the late 1980s, the printing industry as a whole moved
toward a high-volume approach. The 47-gallon drums were
Flow Control
July 2009 15
technology spotlight
be a potential problem for the specific application under consideration here.
Volumetric Linear Piston Meter: Ultimately, the printer decided
to replace its existing meters with a volumetric piston-based
measurement device. This positive-displacement system was
specially designed to eliminate the common drawbacks of piston
meters, such as the connecting shaft and a phenomenon called
the top-dead center. The top-dead center in any conventional
design is a phenomenon of a large degree of crankshaft movement to an extremely small amount of piston displacement.
The replacement meter under consideration here was specially
designed with four piston chambers each of which was recThis is a view of the linear piston meters internal mechanism. Parts
are described in order:
bottom is the port plate,
meter body; inside the
meter body is the rectangular box frame;
next to that is the oscillator; and inside the
oscillator is the valve
disc, which captures the
rotational shaft; and on
top of the shaft is the
magnet wheel.
tangular in shape and developed by sliding components moving on a flat plate. Two of the chambers were one volume size,
while the other two were of a smaller volume size. Unlike conventional piston flowmeters that receive their fluid for displacement
from a valve mechanism delivering it to the piston chamber from
the top, the replacement meter delivered fluid to the piston chamber from the bottom.
In addition, a conventional piston meter typically connects to a
rotational mechanism called a crankshaft, which means it sees a
top-dead center as it maneuvers through the crankshaft rotation.
This generates a diminished amount of flow to an increased
amount of movement. The replacement meter, on the other hand,
used a valve disc as the pivot point for all of its oscillating parts,
delivering measurable material to the chambers. With an opposing milled out design on the valve disc on its bottom, the meter
removed material that had been put into the piston chambers 180
degrees out from one another i.e., when each chamber was
filled as the valve disc was aligning its orifice with the appropriate
piston chamber orifice 180 degrees out, the opposing valve orifice was aligning to empty it. This happened continuously as the
mechanism rotated each chamber being a precise volume of
measurement displacing the same amount of liquid each time.
The mechanism detailed above allowed the replacement piston
meter to eliminate the top-dead center issue typically associated
with conventional piston designs, enabling the meter to maintain
linearity throughout the entire operational RPM range of the
mechanism. With such a consistent linearity, the flowmeter was
This is a typical four-color linear piston meter installation for a high-volume, dual-web heat-set web press that generally consumes 30 and 45
thousand pounds of ink per month.
16 July 2009
Flow Control
technology spotlight
8 Hour Runability Test
was also designed to eliminate the need for
high-pressure seals, it was extremely sensitive
to bi-directional fluid movement. This proved
to be an essential characteristic in the mass
distribution process, as varying pressure levels throughout the distribution system were
found to rock meters back and forth on occasion, thus producing reverse flow in some situations. This reverse flow had been a problem
in the past, as it would further compound
measurement inaccuracy issues. The replacement meter, however, with its capability for
subtracting reverse flow and only adding positive flow to the reading, eliminated this issue.
18 July 2009
Flow Control
Book Em
A Printer Finds Lost Ink On a High-Volume Project
A new metering system provides much-needed
application insight to a printer struggling with a highvolume press run that repeatedly showed a loss.
Production Challenge
With the ink consumption changing from 1.4 pounds per minute
to three pounds per minute, the process was totally out of
control. Plant management and press personnel wondered what
could be the cause of ink consumption rising that fast and where
all the ink was going.
The initial assumption was that the newly installed flowmeter
was defective. The metering system was tested though, and was
determined to be reading accurately. The second assumption was
there must be a leak within the system. Or, perhaps, something
was wrong with the setup of the process line. As such, a decision
was also made to run check on the press and distribution system.
www.FlowControlNetwork.com
was not consuming any gas, and it was at 97.5 percent compliance, meaning it was fueled at 100 percent of the solvents being
flashed off in the dryer. This condition was something the printer
had never seen before. Putting all of this information together, the
printer came to the conclusion that as the temperature of the
press rose throughout the eight-hour run, the ink was excessively
heated, which changed its viscosity to the point that the ink was
actually being absorbed into the paper. (See chart on page 18 for
visual representation of a similar condition.)
Press densitometers are generally designed to automatically
read and correct for all image density and ink coverage and consumption issues. The process conditions experienced in the application under consideration here were interpreted by the densitometer as too much water and ink, when in reality the ink was
going into the paper. But since the densitometer took its reading
as an interpretation of loss of density, it put more ink onto the
paper. Since thats the only thing a densitometer knows to do,
thats what it did, which effectively doubled ink consumption in a
way that was invisible to the naked eye (and the previous ink
metering system).
As a result of this error, this project showed a total loss of
roughly a million dollars.
The Solution
After discovering the problem with the application detailed above,
the printer in question was led to the conclusion that perhaps its
other high-run production projects were also being squeezed in a
similar fashion. The real question, however, was why didnt the
printer see this operational variance before? What was it about its
previous ink meter that didnt pick up on these operational variances? The answer to these questions was actually quite simple.
The previous ink meter featured a leak path that had a direct
relationship to viscosity. So, as the viscosity of the ink was changing with the rising temperature of the press during the high-volume run, the leak rate of the meter increased and readings were
constantly skewed. In fact, readings were skewed to the point that
the 1.5 pounds of ink that was documented at the beginning of
the project looked like 1.5 pounds eight hours into the press run
because of the leakage rate by the meter.
As such, every time the printer printed the type of product
detailed above with high-volume ink coverage for the total project,
it took a loss and yet could not figure out where and why it was
producing at a loss. This was because the operational variance
was invisible with the meter the printer was using and was not
realized until it bolted in the INKnet meter, which provided .1 percent accuracy and self-calibration within a wide range of changing
viscosities.
According to subsequent application analysis, when producing
small print runs, the printer under consideration here estimated
that its previous ink meter was off 1.5 percent to 2 percent. On
large runs that lasted over eight hours, it estimated its ink meter
readings were off by as much as 50 percent.
July 2009 19
technology spotlight
payback, says Rapp. As such, the push to move to a new metering system died out for bit.
The initiative was bumped back up to priority status rather
abruptly when Brown saw four of its existing meters wear through
in the span of one week. INKnet came back to Brown with a new
quote for a stripped down ink metering system, which brought the
price point down enough for Brown to make a purchase.
When I realized that we had to replace all four meters, I was
really adamant that it would be really stupid to replace with the
same meters that we had identified werent really meeting our
needs, says Rapp. As such, he says Brown narrowed its search
for replacement meters to the INKnet meter and a gear-driven
meter that was highly sensitive to changes in flow and highly accurate. Ultimately, Rapp says the decision was to go with the INKnet
meter because Brown was already very impressed with the design
from the earlier demo.
Once the INKnet meters were in place, Rapp says Brown immediately recognized backward flow in the process. The previous
meters were not responding to this backward flow, which was
throwing the accuracy off. In addition, the new meters provided six
pulses for every 40 CCs (approx. 2.400 pulses per gallon), while
the old meter was only providing one click per gallon, regardless of
whether the flow was forward or backward.
One of the key requirements for proper operation of the INKnet
meter is proper filtration ahead of the device. As such, Rapp says
Brown has been working to tailor its application to meet the
required level of filtration. With 100 micron ink filtration, the INKnet
meter has a proven life of more than four years. However, without
filtration, the lifetime of the meter is less than 90 days.
Ultimately, Brown plans to transition all of its ink meters to the
INKnet design. As each of the old meters fails, Rapp says Brown
will replace it with the INKnet meter.
Buffalo News Press (www.buffnewspress.com), a regional fourcolor commercial printer of weekly newspapers, tabloid and broadsheet inserts, booklets and catalogs, started to monitor its ink consumption about nine years ago. At that time, the company invested
in some mechanical gear ink meters, which the company soon
realized were not capable of meeting the application requirements.
20 July 2009
q&a
by Mike Boudreaux
A Primer on SIS
Understanding Process Safety Systems Design
Mike Boudreaux is the DeltaV SIS product manager at Emerson Process Management in Austin, Texas. Prior to joining Emerson, he previously filled various engineering, sales and marketing roles at AkzoNobel and Alcoa. While at AkzoNobel, Mr. Boudreaux gained his experience specifying, designing and implementing safety instrumented systems. He earned a bachelors degree in Chemical Engineering from
the University of Houston and an MBA from the Kellogg School of Management at Northwestern University. He is a member of the ISA 84
functional safety standards committee and he is a co-chair for ISA 99 Working Group 7 on safety and security. Mr. Boudreaux can be
reached at Mike.Boudreaux@emerson.com or 512 832-3547.
Q: How did the concept of safety instrumented systems come to
be? How has SIS design strategy evolved since its inception to
where it stands now?
A: Industry incidents, such as those that have occurred in
Flixborough, England, Seveso, Italy, Bhopal, India, and
Pasadena, Texas, as well as others, have led to an increased
interest in process safety. Much of the focus has been to reduce
process risk through inherently safe design and independent layers
of protection (IPL). Safety instrumented systems are one of the
many layers of protection that are used to deliver increased
process safety.
Modern safety instrumented systems are based on functional
safety design concepts that are provided by IEC 61508 and IEC
61511. Over the past 25 years, SIS design concepts have mirrored
process control system developments. Control systems have
evolved from pneumatics and hardwired panel boards to centralized DCSs to digital plant architectures. Similarly, SISs have progressed from relays and switches to PLCs with redundant architectures to logic solvers with advanced diagnostics capabilities.
SIS design has evolved from using rules of thumb and prescriptive
requirements to designing safety loops based on the functional
safety requirements of the process.
Q: From a general process safety perspective, why are safety
instrumented systems important? What capabilities do SISs
generally offer the end-user for process safety improvement?
A: When a process cannot practically be designed to be inherently
safe, an SIS can be used to reduce risks to an acceptable level. An
SIS can be designed to deliver a specified safety integrity level
(SIL) of risk reduction. IEC 61508 defines SIL 1 through SIL 4,
with each SIL designating a relative level of risk reduction provided
by a safety instrumented function (SIF) by an additional order of
magnitude.
Q: What role do standards play in the world of SIS? What
should end-users know about standards related to SIS?
A: The modern concept for SIS in the process industries is based
on IEC 61508 and IEC 61511. IEC 61508 is a generic functional
safety standard that can be applied across all industries. IEC 61511
22 July 2009
q&a
forming this work are competent in the area of process safety systems design and, more specifically, SIF design and SIL verification.
Q: What are some key steps end-users should take to ensure
they are employing SIS in a way that will provide the most benefit in terms of process safety?
Flow Control
26
July 2009
Flow Control
best practices
by Nwaoha Chikezie
Common Obstacles to
Proper Airflow
Obstacles in a compressed airflow system
alter the pressure of the flowing air. As the
push to optimize production continues, it
becomes imperative for production personnel to always identify and combat such
problems.
Air Quality: Air cleanliness affects the
required airflow. Atmospheric air contains a large amount of airborne contaminants ranging from dust, dirt, water
vapor, and, in an oil related industry, oil
vapor in the form of unburnt hydrocarbons.
In many applications, dirt and dust particles can pass through the air compres28 July 2009
Compressed air flows as a result of pressure differential. This implies that pressure drop is the major
cause of insufficient airflow. To maintain adequate
airflow, much attention should be focused on the
pressure losses that are caused by obstacles in the
compressed air systems.
sor and gradually form deposits on the
interior surface of the compressor. As
these deposits accumulate, friction
increases and the compressor losses it
ability to generate the required
head for airflow.
While many operators are concerned about the risk of dirt and
dust particles, oil vapor and water
vapor in the air stream poses a
problem. During compression, oil
vapor and water vapor escape
with the compressed air, and after
compression the air is cooled in
the interstage cooler, resulting in
condensed vapors. If this condensate is not removed, it causes
corrosion and blockage to the compressed-air systems, thus reducing airflow and production efficiency. To prevent this, filters must be properly located
in the system, and an interstage
cooler with automatic drain traps
must be fitted into the air compressor.
Is it leak free?
Is the distribution-piping aging or corroded? Install a new distribution piping. Check for
moisture content in the air stream, and
install filter along the line.
Confirm status.
Refer for repairs or install a new indicator.
www.FlowControlNetwork.com
Troubleshooting
Quickly diagnosing and correcting application issues will help ensure that small
problems dont become big ones. Thus,
it is important to always keep in mind
the old truism: A problem identified is
half solved. Table 1 provides guidance
on troubleshooting five common problems. FC
Nwaoha Chikezie has previously
worked as an operator (student trainee)
with Port Harcourt Refining Company
(PHRC,
www.nnpcgroup.com/index.php) in
Nigeria, and is currently working on
several research projects involving flow
systems design, including an initiative
with the Caribbean African Student
Exchange Initiative (CASEI). As part of
his research, Mr. Chikezie has authored
a number of engineering articles in
leading international journals. Mr.
Chikezie is a member of SPE, ASME,
AIChe, IMechE, ICE, IGEM and Nigerian
Gas Association (NGA). He can be
reached at +234-703-135-3749, or
chikezienwaoha@yahoo.com.
July 2009 29
best practices
by Nwaoha Chikezie
30 July 2009
Remedy
Remedy
Founded in 1905, Badger Meter, Inc. has developed and markets a comprehensive
range of flow meters and control valves serving a multitude of Industrial flow control and
measurement applications. Badger Meter is a long established manufacturer of various
flow measuring technologies including positive displacement, turbine and electromagnetic.
Badgers line of precision control valves provide innovative and high quality flow control
solutions over a wide range of liquid and gas applications.
If your application requires accurate and repeatable flow measurement and control,
expert technical advice and long term support and commitment, then let BADGER
be your ONE STOP SOLUTION.
:HVW %URZQ 'HHU 5RDG 32 %R[ 0LOZDXNHH :,
)D[ (PDLO IORZ#EDGJHUPHWHUFRP
Circle 18 or Request Info Instantly at www.FlowControlNetwork.com
best practices
approaches; the exchanger duty and log mean temperature difference. A low approach difference will give a corresponding log
mean temperature difference, and high load vice versa. When the
operating temperature limits are exceeded, the material condenses
as a result of deposits and coats the internals of heat exchangers,
which produces a wall temperature that is lower than the bulk limit
temperature. To maintain the operating temperature, the inlet and
outlet temperature must be monitored (Table 1).
Effects of nature and properties of heat exchanger: Regarding
Troubleshooting
As with any piece of process equipment, efficient and effective
troubleshooting is key to long-term operational success. When
considering a heat exchanger in particular, the first step in the
troubleshooting process should be to make sure that the operating
variables are maintained and controlled at the designed point.
Table 1 provides guidance on troubleshooting two common heat
exchanger problems. FC
Nwaoha Chikezie has previously worked as an operator (student
trainee) with Port Harcourt Refining Company (PHRC, www.nnpc
group.com/index.php) in Nigeria, and is currently working on several research projects involving flow systems design, including an
initiative with the Caribbean African Student Exchange Initiative
(CASEI). As part of his research, Mr. Chikezie has authored a number of engineering articles in leading international journals. Mr.
Chikezie is a member of SPE, ASME, AIChe, IMechE, ICE, IGEM
and Nigerian Gas Association (NGA). He can be reached at +234703-135-3749, or chikezienwaoha@yahoo.com.
Circle 19 or Request Info Instantly at www.FlowControlNetwork.com
32
July 2009
Flow Control
Endress+Hauser, Inc
2350 Endress Place
Greenwood, IN 46143
inquiry@us.endress.com
www.us.endress.com
Sales:
888-ENDRESS
Service: 800-642-8737
Fax:
317-535-8498
Thanks,
Bill H., PE
###
I taught high school science for many years, including chemistry
and physics. I noticed that I could divide my students into two
groups one group had a good deep understanding of math and
could apply it well to solve new problems; the other group could
do the math, but had no clue what they were doing, why they
were doing it, what it meant, or how to apply it to something
new. Both groups were otherwise equal. I never did figure out why
they were different.
Ray M.
###
A vessel-to-vessel
pipe system with
elevation differential
You state that the flow is proportional to speed ... and develop
relationships from there. This is correct in the application that you
cite/sketch, so the article is technically correct.
However, this is usually not the case. In particular, you show the
tank level to be above the return pipe so the pressure upstream
and downstream of the pump at zero flow is the same. Therefore,
there is no static head to overcome and any (non-zero) pump
34 July 2009
Flow Control
INNOVATIVE
IN
NOVATIVE
E SPRAY
SPR AY ENGINEERING
E NGINE E RING
Injection Systems for SCR, SNCR,
and FGD Scrubber Applications
Twinabsorb offers you:
r 9LK\JLK VWLYH[PUN JVZ[Z
r 4H_PT\T ZJY\IIPUN HJ[PVU
r ,HZ` [V YL[YVMP[
pumps in open and closed loops for recirculated service water, chill water, boilers, air conditioning and hydronic loops.
There are more of these types of pumps
and systems in Manhattan proper than
all the process pumps in the surrounding NYC boroughs, plus Connecticut
and New Jersey (and maybe Delaware
and Vermont, too). We could say the
same for Houston, Peoria or Daytona
Beach.
Remember too, that even a pharmaceutical plant, oil refinery, or paper mill
will have many pumps in open and
closed pipe loops, although pumps in
vessel-to-vessel pipe systems will outnumber the loop systems that dont feature static head.
If we consider the number of pumps
re-circulating water in public and private
swimming pools, fountains, hot tubs,
spas and aquariums, the case is even
stronger for loop pumps in systems that
dont feature static head.
And, most automobiles (except
Porsches and old VWs) will have a radiator water pump moving cooling water
through a closed pressurized loop. And
amazingly, these pumps are variablespeed pumps. The velocity is a function
of your foot on the gas pedal.
As a pump-user advocate and maintenance practitioner, I say there are
many more pumps in open and closed
re-circulation loops (with no static
head) than pumps in vessel-to-vessel
pipe systems with static head. I believe
that sketch and the application will
ring the bells of most readers of
Flow Control. FC
Keep in touch,
Larry Bachus (a.k.a. Pump Guy)
Lechler Headquarters
Lechler,
L
echler, Inc.
Inc .
445 Kautz
445
Kaut z Rd.,
Rd., St.
St . Charles,
Charles, IL
IL 60174
60174
P
hone: 630.845.6817
630.845.6817
Phone:
F
a x: 630.845.6917
630.845.6917
Fax:
www.LechlerUSA.com
w
w w.LechlerUSA .com
environmental@LechlerUSA.com
e
nvironment al@Le
L chlerUSA .com
P R E C I S I O N ENGINEERED
E N G I N E E R E D SPRAY
S P R AY NOZZLES,
N OZ Z L E S , SYSTEMS,
SYS T E M S , AND
A N D EQUIPMENT
EQUIPME NT
PRECISION
www.bachusinc.com
Circle 22 or Request Info Instantly at www.FlowControlNetwork.com
36 July 2009
Flow Control
Get Your
Pump Guy Diploma
"Excellent course. I only wish I had this course
10 years ago. No one has ever explained to me
how a pump curve works (even college) or
how to apply a system curve to a pump curve.
Thank you for your easy-to-understand, practical
course." Comment from an attendee at the
May 27-29, 2009 Pump Guy Seminar in New Orleans
www.flowcontrolnetwork.com/events.asp
www.FlowControlNetwork.com
July 2009 37
new products
FREE PRODUCT INFO: For FREE PRODUCT INFO, circle the numbers listed with each product in the FREE INFORMATION section on the reader service card bound in this issue of the magazine, or visit www.FlowControlNetwork.com and click on
the FREE PRODUCT INFO link to use circle numbers online.
Dynasonics TFX
Ultra clamp-on
ultrasonic flow
and energy
meter is
designed to provide accurate and
repeatable flow
measurement readings
for full pipe liquid applications, such as cooling lines, raw sewage flows, water
distribution and processes where system shutdown
is impossible. The TFX Ultra is also available as an
energy flowmeter measuring energy usage in BTUs
or Tons. Since the meter is a clamp-on device, there
is no need to shut down the process for installation
or maintenance, and the meter can be installed and
fully operational in minutes. With no moving parts,
there is no risk of mechanical wear. Features a compact aluminum enclosure, digital display, bi-directional flow measurement, and a totalizer featuring
forward, reverse and net total, and Modbus communications. An optional Ethernet connection and USB
programming port are also available.
FREE PRODUCT INFO: CIRCLE 107
ExtremeTemperature Turbine
Flowmeter
Flow Technologys
FT/DF (Diesel Fuel)
turbine flowmeter system is designed to
provide accurate
measurements of
diesel fuel consumption in a wide range of
industrial applications,
including automotive,
marine, aerospace and
power generation. Pairing Flow Technologys FT
Series turbine meter with the companys LinearLink
Temperature Compensated Interface (TCI), the FT/DF
system can accurately measure diesel fuel at temperatures as low as -50 F. The turbine flowmeter incorporates a fail open technology, which, in the event of a
malfunction, continues to feed fuel to the generator
ensuring there is no interruption of power to the
industrial operation.
FREE PRODUCT INFO: CIRCLE 108
Flow Control
Control
Reliable, stable and smooth gas mass flow control is
now within reach thanks to the proprietary Sierra
Frictionless-Hovering Valve TechnologyTM inside every
Smart-Trak 2. Experience the most advanced directacting control valve available, and unlike other
valves, it has shut-off capability.
Independence
With Smart-Trak 2, independently adjust calibration
in the field for any of the 10 pre-programmed
Dial-A-Gas gasses. The user-friendly Pilot Module
control/readout interface lets you view and adjust
critical control functions at any time.
Flexibility
Plug our innovative new CompodTM into the face of
your Smart-Trak 2 to streamline, simplify and save!
Smart-Trak 2 becomes a fully network-enabled, multidrop RS-485 / Modbus RTU device, allowing you to
reduce costs by automating complex gas processes
like gas mixing, gas ratio control, batch control, leak
testing and process monitoring.
Visit sierrainstruments.com/st2
NORTH AMERICA
5 Harris Court, Building L / Monterey, CA 93940 / U.S.A.
800.866.0200 / 831.373.0200 / fx 831.373.4402
ASIA-PACIFIC
Shanghai, China
+8621 5879 8521/22 / fx +8621 5879 8586
EUROPE
The Netherlands
+31 72 5071400 / fx +31 72 5071401
new products
Indicating Differential-Pressure Switch
Mid-West
Instruments
Model 121 indicating differentialpressure switch
is a heavy-duty
version of the
companys Model
120 design, featuring the same
rugged, fieldproven piston/housing. In addition, the heavy-duty industrialtype terminal strip can support either one or two switches.
Wiring is easy with 1/2 NPT conduit interface and a removable cover. A variety of switching configurations is available
with one or two hermetically sealed switches in SPST, SPDT
configuration with 240 volt, 3 Watt or 60 Watt ratings. The
switch is available in aluminum or 316 S.S. pressure housing
with 316 S.S. and ceramic internal parts. Safe Working
Pressure is 6000 PSIG (0-400 bar). Differential pressure
ranges from 0-5 PSID (0-.3 bar) to 0-110 PSID (0-7 bar) with
+/-2 percent accuracy. The weather-resistant gauge front is
reinforced engineered plastic for corrosion resistance.
FREE PRODUCT INFO: CIRCLE 109
Do You
Know & Understand
Your Pumps?
Larry Bachus ("The Pump Guy") is the
co-author of Everything You Need to
Know About Pumps, one of the best
selling technical books on pump systems in
the world. This book is written exclusively for
people who must maintain pumps. Whereas
other pump books are written from a design
point of view, this book is written with
maintenance in mind. While most technical
books sit on a reference shelf gathering dust,
this book gathers dirt smudges. Its pages get
creased and folded when mashed by the lid
of a photocopy machine. It gets sneezed on
and splashed with snot on cold mornings. It gets soaked with leaking oil, grease,
and coffee. Basically, it gets used ... because it's tremendously useful. The
straightforward guidance it provides will help you ensure the efficiency and
lifespan of your pumping systems.
www.bachusinc.com/books.htm.
Differential-Pressure Flowmeter
McCrometers
V-Cone flowmeter is a corrosion-resistant
device designed
for high-accuracy
measurement
with virtually no
maintenance
under challenging conditions.
The flowmeter is
based on advanced differential-pressure technology and
requires no moving parts. Built-in flow conditioning allows
the flowmeter to achieve measurement accuracy of +/-0.5
percent, with a repeatability of +/-0.1. The meter operates
over a flow range of 10-to-1 and services line sizes from
0.5 to 120 inches. Standard configurations may be specified with either stainless steel or carbon steel materials.
Optional materials include Hastelloy C-276, Duplex 2205,
Chromeloy P22/P11, Monel K400/K500, Inconel 625 and
many more. With its ability to self-condition flow, the
flowmeter saves space, eliminating the need for up/down
stream straight-pipe runs required by other DP technologies, such as orifice plates and Venturi tubes.
FREE PRODUCT INFO: CIRCLE 110
40
July 2009
Flow Control
Thermo Fisher
Scientifics M-PULSe
multi-path ultrasonic
flowmeter is capable of
measuring fluids accurately from as low as
0.06 cSt up to 1,500 cSt.
The systems wider viscosity range was determined during recent testing and indicates its ability to further
optimize use of multi-product hydrocarbon pipelines. The
meter enables pipeline operators to run thick crude followed
by gasoline with no recalibration required between the hydrocarbons. To fulfill larger pipe requirements, the meter now features an extended spool size range to include 500 mm (20inch) and 600 mm (24-inch) spools along with the standard
100 mm (four-inch) to 400 mm (16-inch) spools. All spool
sizes measure as low as 1 ft/s and as high as 50 ft/s to provide the highest turndown ratio of 50-to-1. Users seeking to
reduce costs also now have the option of an economical carbon steel model in addition to the standard stainless steel. The
flowmeter has no moving parts and does not require calibration following replacement of a transducer which helps minimize maintenance and downtime. Accuracy of +/- 0.10 percent
of flow and repeatability of +/- 0.02 percent.
FREE PRODUCT INFO: CIRCLE 115
www.FlowControlNetwork.com
July 2009 41
Advertising Section
Literature Reviews
Thermal Mass Flow
Eldridge Products Inc.s full color catalog
includes the expanded Master-Touch
flowmeter product line for thermal gas
mass flow measurement. The product line
includes the patented Flow Averaging
Tubes for large ducts and/or difficult installations, and the LightWIRE infrared communications modules. To request a catalog, call 800 321-3569 or visit
www.epilfow.com.
FREE INFO: CIRCLE 200
Linear-PD Flow
Measurement System
INKnet Systems/Link-Techs Smart
Meter positive-displacement flow
measurement system features an
internal risk-based processor for
extended internal memory and
self-diagnosis. The meter provides 0.1 percent accuracy
when measuring either low- or
high-viscosity and thixotropic materials. The meter is impervious to
pressure changes running from 5
PSI to 5000 PSI. For more information and to request literature visit
www.inknetsystems.com or call 262 695-0499
FREE INFO: CIRCLE 201
42 July 2009
Advertising Section
Resource
Marketplace
FIND NEW
SUPPLIERS,
BUY/SELL USED
EQUIPMENT
AND MORE
IN THE
FLUID HANDLING
RESOURCE
MARKETPLACE
We Know Flow!
Consumer Guide to
spitzer and boyes, llc
complete consulting services
market research
comparative analysis
technology transfer
expert testimony
seminars
www.spitzerandboyes.com
or call +1 845-623-1830
Circle 27 or Request Info Instantly at www.FlowControlNetwork.com
www.FlowControlNetwork.com
July 2009 43
Advertising Section
www.signicast.com
Industry Leader in
Investment Castings
www.checkall.com
www.smartflow-usa.com
www.harwil.com
www.veris-inc.com
No-Straight-Run Flowmeter
www.vici.com
www.norenproducts.com
44 July 2009
Flow Control
Advertiser Index
Find company Web sites and get free product information online at www.flowcontrolnetwork.com. Click on the Free Product Info link under the Current
Issue on the left-hand side of the page.
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
Name
Page
RS #
Name
Page
43
NA
Alicat Scientific
35
21
Rosemount
Assured Automation
Endress+Hausers Inc
40
23
IBC
31
18
25
16
Flow Technology
Brooks Instrument
10
FMC Technologies
13
RS #
Max Machinery
30
Niagara Meters
41
26
43
28
44
211
1, 42
2, 204
33, BC 20, 31
Sanisite
seepex Inc
44
209
Harwil
44
210
Eldridge Products
INKnet Systems/
27
17
19
13
1
15
18
IFC
INVALCO
GF Piping Systems
Collins Instrument
213
44, 48 208, 32
Kuriyama of America
Link-Tech
RS #
36
44
Products
Page
Lechler Inc
Smartflow
CME Aerospace Control
Name
42
201
Interstate Specialty
32
Sierra Instruments
39
25
Signicast
44
212
43
27
Spraying Systems Co
5, 43
4, 206
Products
11
Teledyne Hastings
45
29
Instruments
43
207
16
11
21
14
Veris Inc
44
214
44
215
PRODUCT INDEX
Page
38
104
Blue-White Industries
38
105
Dwyer Instruments
38
106
Dynasonics
38
107
Flow Technology
38
108
Products
26
100
Lubrizol Corporation
26
101
McCrometer
40
110
40
111
Mid-West Instrument
40
109
Omega Engineering
41
113
41
114
102
41
115
26
103
Interstate Specialty
46 July 2009
Flow Control
think tank
Level Measurement
CAPACITANCE: The property of a system of conductors and dielectrics that permits the storage of electricity when potential differences exist between the conductors
DIELECTRIC: A non-conductor of electricity, especially a substance with electrical
conductivity less than a millionth of a siemens
I would like to receive/continue Flow Control magazine: _____ Yes _____ No.
Signature:
Date:
Name:
Title:
Company:
Address/City/State/Zip:
MICROWAVES: the term for the electromagnetic frequencies occupying the portion of the radio frequency spectrum from 1 GHz to 300 GHz
Phone:
E-Mail:
OUTPUT: the signal that is transmitted as information from a level device to some
type of PLC
PARAMETERS: in programming, the variables that are given constant values for
specific purposes or processes
RADAR: a device that radiates electromagnetic waves and utilizes the reflection of
such waves from distant objects to determine their existence or position
RANGE: the distance from the transmitter to the material in a vessel
REACTOR: a vessel that contains usually a mixture of different constituents stirred
together and under pressure and temperature to derive an end result concoction
REPEATABILITY: the closeness of agreement among repeated measurements of
the same variable under the same conditions
STILLING WELL: something that is mounted inside of a vessel perpendicular to
the vessel wall, and is open to the vessel at the bottom
ACCURACY
RADAR
CAPACITANCE
RANGE
DIELECTRIC
REACTOR
FREQUENCY
REPEATABILITY
LEVEL
STILLING WELL
MICROWAVES
TRANSDUCER
NOZZLE
TRANSMITTER
OUTPUT
TURBULENT
PARAMETERS
www.FlowControlNetwork.com
TRANSDUCER: a device or sensor that converts input energy of one form into
output energy of another
TRANSMITTER: an electronic device that generates and amplifies an electronic
signal and transmits the electronic signal to some smart type controller
TURBULENT: violently agitated or disturbed and having a restless or high motion
crest to wave surface
This glossary of terms and definitions was contributed by Jerry Boisvert, product
manager of Microwave Technology for Siemens Energy & Automation
(www.sea.siemens.com/ia). Mr. Boisvert can be reached at
jerry.boisvert@siemens.com.
July 2009 47
think tank
flow measurement system consists of a flowmeter element, transmitter and indicator. If each of the three components has an accuracy of 1 percent, the performance of the flow measurement system is
approximately:
A. 3 percent
B. 1.7 percent
C. 1 percent
D. None of the above
by David W. Spitzer
lated by taking the square root of the sum of the squares of the
effect of each component. For this system, this would be calculated
as the square root of (12 + 12 + 12), or 1.73 percent. It might
appear that Answer B is correct, however further investigation would
show that the flowmeter element has a percentage of rate error,
while the transmitter and indicator have percentage of full-scale
errors. This means that the transmitter and indicator exhibit flow
errors in excess of 1 percent at flows below 100 percent of full-scale
flow. Therefore, the calculation that results in 1.73 percent performance is only correct at full-scale flow. Answer D is correct.
Commentary
The performance of the flow measurement system should be inferior to the performance of the flow element itself. Answer C could be
viable (given approximate in the wording of the question).
However, the magnitude of the performance of the other two components (1 percent) causes Answer C to be incorrect.
It is not often that all of the components in a measurement system
are in error by the maximum amount in the same direction at the
same time. Therefore, the errors for the three components in this
system would not be mathematically added to obtain 3 percent.
Answer A is not correct.
The overall accuracy of measurement systems is typically calcu-
www.spitzerandboyes.com
Model 60B Flow
Computer
Save downtime and money with the FCS 9003 portable Flow Calibrator. It utilizes
a custom Windows based program to provide superior calibration of many
different flowmeter types. The portability of the system saves test time and the
software compensates for flowmeter types and test conditions eliminating manual
calculations. Print and store compliance data reports after each calibration.
For more information on the Model 60B Digital Flow Computers, the FCS
9003 Portable Calibrator or any of these CME products:
Laminar Flow Elements Mass/Volumetric Digital Flowmeters Custom Test
Stands Analog Flowmeters Digital Manometers & Altimeters
Call Rich Kennedy, 800-845-0927
48 July 2009
Flow Control
Endress+Hauser, Inc
2350 Endress Place
Greenwood, IN 46143
inquiry@us.endress.com
www.us.endress.com
Sales:
888-ENDRESS
Service: 800-642-8737
Fax:
317-535-8498