Flow Control August 2012 PDF

Plan 23 Mechanical Seal Design • Trends In Coriolis & Ultrasonic Flowmeters • SCADA Security
AUGUST 2012฀Vol.฀XVIII,฀No.฀8฀•฀www.FlowControlNetwork.com
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© COPYRIGHT 2012 OMEGA ENGINEERING, INC. ALL RIGHTS RESERVED
®
august 2012
Vol. XVIII, No.8
features 20
14 Do Your Thermowells Meet the ASME
Standard? thermowell design has become more
conservative in light of a new standard
20 Establishing a Mechanical Seal Baseline

calculation method for Plan 23 systems in hot water service
API Plan 23 has proven to be the most effective way of
sealing hot fluids in centrifugal pumps from a reliability,
26 Gaining New Ground safety and economic perspective.
reference recorders shake things up in the oil & gas industry
26
28 Leading the Way
strong r&d drives coriolis & ultrasonic flowmeters to new heights
columns
4 VIEWPOINT the pursuit of continuous quality improvement
12 APPLICATIONS CORNER
variable-speed drive energy savings
32 AUTOMATION FILE
why scada security matters for flow control professionals Reference recorders are replacing chart recorders for a
variety of applications.
36 THE PUMP GUY ‘the energy audit’
36
departments
47 THINK TANK microelectromechanical systems (MEMS)
48 QUIZ CORNER charles’ law
products Epoxy coatings can extend the service life of a water pump,
24 FOCUS ON: temperature measurement >>>>> but can they actually improve the pump’s efficiency?
Flow Control (ISSN #1081-7107) is published 12 times a year by Grand View Media Group,
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© Entire contents copyright 2012. No portion of this publication may be reproduced in any
46 ADVERTISER/ E-mail: [email protected] form without written permission of the publisher.
PRODUCT INDEX 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
Subscribe/Renew/ recommendation by the publisher. Editorial contributions are accepted from the fluid handling
On the Cover: The thermowell assembly Change of Address: industry. Contact the editor for details. Product/service information should be submitted in
accordance with guidelines available from the editor. Editorial closing date is two months prior
photo is courtesy of JMS Southeast www.flowcontrolnetwork.com/subscribe to the month of publication. Advertising close is the last working day of the month, two months
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2 August 2012 Flow Control

viewpoint
Continuous Quality Improvement G R A N D

GV
V I E W M E D I A G R O U P
L
ike most organizations programs, including the American ®
engaged in a serious pursuit Society of Business Publication

of success, here at Flow Editors’ “Azbee Awards”; the
Control we aim for continuous Trade Association Business PUBLISHER
quality improvement. And while Publication International’s JOHN P. HARRIS | (205) 408-3765
[email protected]
this is our end goal, and we for- “Tabbie Awards”; and the
mally discuss how we can be a Magazine Association of the ASSOCIATE PUBLISHER
MICHAEL C. CHRISTIAN | (732) 200-5963
better Flow Control on the first Southeast’s “GAMMA Awards.” [email protected]
Monday of every month, I’d be In all, Flow Control has won 11
EXECUTIVE DIRECTOR OF CONTENT
lying if I said there weren’t times publishing industry awards since MATT MIGLIORE | (610) 828-1711
[email protected]
when we’re in such a rush to get 2006.
things done that it’s hard to imagine our level While this year’s APEX Awards recognized MANAGING EDITOR
of quality does anything but suffer. Still, I a specific article—our January 2011 AMY W. RICHARDSON | (859) 317-9763
[email protected]
believe the constant dialogue we have about “Viewpoint” editorial, “The Truth About Shale
quality improvement creates an inertia that Gas” (page 4)—to me this award recognizes COLUMNISTS
LARRY BACHUS;
inevitably leads us to do and be better. more. It validates that even though our pur- DAVID W. SPITZER; JESSE YODER
ART DIRECTOR
JULIE FLYNN
I believe the constant dialogue we have about quality [email protected]
improvement creates an inertia that inevitably leads

MARKETING MANAGER
MARY BETH TIMMERMAN
us to do and be better. SUBSCRIPTION & REPRINT REQUESTS:

[email protected]
For example, last month while we were suit of quality may vary in effectiveness from Administrative Team
racing against time to meet the deadline for time to time, we are on the right path. And GENERAL MANAGER
BARRY LOVETTE
the issue you’re now reading, we learned with this sentiment in mind, I would like to VICE PRESIDENT OF OPERATIONS
that Flow Control was recognized with an congratulate the entire Flow Control team for BRENT KIZZIRE
“Award of Excellence” in the 24th annual a job well done. Everybody on our staff— VICE PRESIDENT OF MARKETING
HANK BROWN
APEX Awards (www.apexawards.com). Flow John Harris, Michael Christian, Amy W. DIRECTOR OF CIRCULATION & FULFILLMENT
Control was one of nine winning entries Richardson, and Julie Flynn—is equally DELICIA POOLE
CIRCULATION ANALYST
in the “Editorial & Advocacy deserving of the recognition ANNA HICKS
Writing” category in a com-
petition that, all told, received
WINNER the APEX judges have
bestowed upon us. I would
VICE PRESIDENT OF FINANCE
BRAD YOUNGBLOOD
more than 3,400 nominations. also like to thank our EDITORIAL ADVISORY BOARD
Larry Bachus: Bachus Company Inc.
In addition to this year’s administrative team, who Gary Cornell: Blacoh Fluid Control
award, Flow Control has won does all of the heavy lifting Jeff Jennings: Equilibar LLC
Peter Kucmas: Elster Instromet
five other APEX “Awards that is required to get Flow Jim Lauria: Water Technology Executive
of Excellence” since 2006, Control’s many print, Web, James Matson: GE Measurement & Control
John Merrill, PE: EagleBurgmann Industries
including 2011 “Magazine and e-media products Steve Milford: Endress+Hauser U.S.
Series” for a six-part feature where they need to be, David W. Spitzer, PE: Spitzer and Boyes LLC
on pumping systems optimiza- when they need to be— Tom Tschanz: McIlvaine Company
John C. Tverberg: Metals and Materials
tion; 2010 “Technical Writing” without all of you, Flow Consulting Engineers
for its July 2009 “Spilled Control could never happen. Jesse Yoder, Ph.D.: Flow Research Inc.
Ink” cover story; 2009 “Best Cover” for its Here’s to another award-winning year, and I WINNER WINNER
March 2009 “In Boom” cover concept; 2008 look forward to working with the rest of the
“Editorial & Advocacy Writing” for its August Flow Control team to bring you, our readers,
2007 “How Clean Can Clean Coal Be?” a continuously improved product in the year, WINNER WINNER
“Viewpoint” editorial; and 2006 “Best Cover” and years, to come. FC

for its July 2005 “Ant Man” cover concept.
WINNER
Flow Control has also been recognized by – Matt Migliore, Executive Director of Content
other leading business publication awards [email protected]

news & notes
APPLICATION NOTE: Putting Flowmeters to the Test

A closer look at a cold water testing facility for magmeters
How Flow Tests Determine
P
recision and quality are critical
requirements for flow measurement Meter Accuracy
instruments, no matter what the The magmeter, which consists of
application or industry. From metering a detector within the flowstream
residential and industrial water use to and an amplifier for processing the
measuring flowrate in water treatment, information, is used as a reference
wastewater, chemical, food and beverage, meter for controlling the flowrate
etc., accuracy is essential. of water passing through the test
As a producer of flow measurement solu- stand. Based on the magmeter’s
tions, Badger Meter (www.badgermeter. reading, a technician opens or
com) employs comprehensive product closes a control valve to adjust the
development and testing at its Milwaukee flowrate up or down, repeating the Research control valves and electromagnetic meters
headquarters in the James O. Wright process until the targeted flowrate (magmeters) are installed on all flow test lines in Badger
Meter’s Hydro Lab.
Innovation Center—one of the largest cold for the test is displayed on the Photo courtesy of Badger Meter
water testing facilities in the world. magmeter. The control valve then
At the Innovation Center, Badger Meter remains in this position for the duration of alternately, have an encoder installed
replicates the water sources found in resi- the accuracy test. in place of the register to perform this
dential, commercial and industrial applica- While the magmeter approximates the function. A programmable logic controller
tions using a reservoir with 125,000 gal- desired flowrate, the actual flowrate for (PLC) is utilized to set the flowrate using
lons of water, assorted pumping systems, any given test is determined by weighing data from the reference magmeter. It also
and a weir tower. From basic mechanical the water after each test, applying tem- instructs the control valve to open or close
functionality to network connectivity, perature correction factors to determine its to adjust the flowrate, begins and stops
products undergo rigorous testing and density, and dividing the calculated volume the test, collects the data from the meter
improvement processes using extreme by the time over which the test occurred. output and scale, and calculates as well as
and strict standards to ensure exacting, In addition to manual testing, certain records the test results.
reliable operation. test stands are designed for automated Magmeters are well suited for most
meter testing. For an automated accu- water applications, including potable
Control Valves & Magmeters Are racy test the meter must have a register water, wastewater, or reclaimed water.
Essential to Product Testing capable of outputting real-time data or, They will measure bi-directional flow and
Research control valves and elec-
tromagnetic meters (magmeters)
are installed on all flow test lines in
the center’s Hydro Lab. The Hydro
Lab includes nine operational test
stands designed specifically for test-
ing meter accuracy using gravimetric
standards.
The control valves and magmeters
are used to set and maintain flow-
rates for meter testing. With their high
accuracy rating and dependability,
magmeters are well suited for flow-
metering tests. The magmeters pres-
ent very little pressure loss and oper-
ate over a wide range of flowrates,
while an array of control valve offer-
ings, with the flexibility for customiza- The Hydro Lab in Badger Meter’s Innovation Center includes nine operational test stands designed spe-
tion, easily meets the wide flow range cifically for testing meter accuracy using gravimetric standards.
Photo courtesy of Badger Meter
required to test various meter sizes.

perform well in many chemical, pharma- to another. Three Badger Meter Research geted flow ranges. In addition, the valves
ceutical, and food and beverage applica- Control Valves are typically installed on communicate with the test stands’ PLC to
tions, as long as the fluid is somewhat each small meter accuracy test stand. A set and maintain the flowrate when used
electrically conductive. single Series 9100 Valve is used to control in the automatic test mode.
the higher flowrates on the stands and In the 12 years the Innovation Center
Research Control Valves Provide two smaller Research Control Valves are has been open, Badger Meter engineers
Exacting Precision used to control low and ultra-low flows. have needed to perform only minimal
Control valves that meet the wide flow Standard valves are used with custom service to the magmeters and research
range required to test meter sizes, ranging trims selected to specifically meet tar- control valves.
from 0.25 to 2 inches, are used exclu-
sively on the small meter accuracy test
stands to precisely control the flowrate.
Without this precision, it is difficult to
replicate exact flowrates from one test
movers & shakers
Alicat Brings in Barger to
Lead R&D, Engineering
Alicat Scientific Inc. (www.alicatscientific.
com) has appointed veteran engineer
Michael Barger as Vice President of
Product Development for the company’s
line of pressure and mass flowmeters,
controllers and accessories. Barger will
lead the product development team in
increasing and enhancing Alicat’s range of
flow control products. Building on Alicat’s
patented laminar flow differential-pressure
technology, he will guide R&D, design, and
engineering activities.
Rotork Names Withers Technical

Director of Its Controls Division
Andrew Withers has been appointed
Technical Director for Rotork Controls
(www.rotork.com), the electric valve
actuation division of the global Rotork
flow control engineering group. In his new
position, Withers will be responsible for
new product developments and research
functions involving all of Rotork’s electric
®
actuator product lines.
Shanahan Named President of

Emerson’s Roxar Business Unit
Emerson Process Management (www.
emersonprocess.com) has named Bret
Shanahan president of its Roxar business
unit, an international technology solu-
tions provider. Prior to taking up the role
of President of Roxar, he was Managing
Director of Emerson’s Roxar instrumenta-
tion division, Roxar Flow Measurement.
www.FlowControlNetwork.com August 2012 7

news & notes
trendlines
Programmable Logic Controllers Lead I/O Market in 2011

The world market for I/O modules, espe- (PLCs, DCS and industrial PCs), the most growth. On the other hand, demand for
cially for Programmable Logic Controllers commonly used products in industrial process automation has lagged somewhat.
(PLC) I/O modules, recovered quite strong- automation. The world recession hurt the Cash flows for those projects were cut off
ly after the recession with double-digit industrial automation market, with the because of the recession and this situation
growth in both 2010 and 2011, according market for each controller type falling continued even into 2011. Thus, the mar-
to a recent report from IMS Research more than 20 percent from 2008 to 2009. ket for DCS I/O modules, which is closely
(www.imsresearch.com). However, the The I/O market also decreased due to the associated with the process industries,
report found recovery of the Distributed lower demand for controller products. grew slower than that for PLC I/O mod-
Control System (DCS )I/O market was “The recovery since 2010 was quite ules. However, worldwide PLC I/O module
somewhat slower. exciting,” commented market analyst Alex revenues make up more than half of the
I/O modules, which are mostly used Hong, in a prepared statement. “As the total I/O module target, which thus had
with controllers, are essential compo- entire I/O module market has benefited quite strong growth.
nents in complex industrial automation from the recovery of the controller market, “Overall, the I/O module market will still
systems. IMS Research says by adding especially that for PLCs.” The entire I/O benefit from a growing PLC market in the
more I/O modules, the scope and flexibility module market grew more than 20 per- foreseeable future,” Hong said. However,
of an entire automation system can be cent in 2010, and more than 10 percent growth in the PLC and DCS I/O module
enhanced. PLCs, for example, can move further in 2011. The main contribution demand will differ, mirroring the differing
toward their control capability to the field to growth came from PLC I/O modules performance of the discrete and process
level by adding remote I/O modules. There because of blooming machine-builder automation markets.”
are many active vendors in this market, markets, IMS Research reports.
including suppliers of a complete range Machine builder markets, especially For more information on this report,
of automation products and specialists, in Europe and Asia, hold a strong posi- visit www.imsresearch.com.
which mainly provide I/O modules. tion. Because they use PLCs widely, the
Broadly, I/O modules can be segmented demand for the I/O modules, which are
into three categories by controller type attached to the PLCs, also enjoyed strong
Semiconductor Flow Control & Treatment Market to Reach $2.3 Billion in 2012
Semiconductor manufacturers will spend treatment products, according to a report also have to be built to eliminate contami-
$2.3 billion in 2012 for flow control and by McIlvaine Company (mcilvainecompany. nation.
com). This includes products used to One of the recent design changes is to
extract water from sources, purify it for reuse water where possible. Rinse water
World Semiconductor Flow use in chip washing and other purposes, which was delivered to a tool but not used
Control and Treatment 2012 and to purify effluent prior to discharge. can undergo less stringent treatment than
The water used in semiconductor water that was used as incoming plant
Revenues processing needs to be extremely pure. water.
Product $ Millions
Water from a river or even water already The semiconductor industry is growing
Pumps 149 processed in a municipal drinking water at rates faster than GDP thanks in part to
plant must be subjected to a series of photovoltaic production, as well as mobile
Valves 449 steps, which often include granular media communications, according to McIlvaine.
filters, cartridges, reverse-osmosis, ion Asia is the largest producer, and McIlvaine
Cross-flow Membranes 236 exchange and degasification. The water predicts it will continue to outpace other
must be carefully monitored for a number markets, as China gains on Korea, Taiwan
Cartridges 485 of parameters. For example, dissolved oxy- and Japan in the semicon space.
gen must be measured and controlled at a The demands for even more pure water
Sedimentation/ few parts per billion. are increasing as the line sizes on the
50
Centrifugation The pumps and valves used in pro- chips are decreasing. This aspect, coupled
cessing the ultrapure water are uniquely with the opportunity for water reuse, are
Monitoring 140 designed to minimize any contamina- creating new opportunities, says McIlvaine.
tion. This includes special materials of
Total 2,309
construction. The piping, tanks and other For more information,
Source: McIlvaine Company components of the ultrapure water system visit www.mcilvainecompany.com.

trendlines
Industrial Valve Sales To Exceed $55 Billion in 2013

Sales of industrial valves and actuators of large independent actuator companies nies generate revenues from $900 million
will exceed $55 billion in 2013, according sell to the original equipment manufactur- down to $600 million. The third tier of five
to the latest forecasts in Industrial Valves: ers and also directly to the end-users. valve companies has sales in the range of
World Markets published by the McIlvaine The top five valve companies account $450 million to $600 million.
Company (mcilvainecompany.com). for 15 percent of the total market with
Energy applications will account for sales ranging from $2.1 billion down to For more information on this forecast,
nearly 40 percent of the total revenues $900 million. The next five valve compa- visit www.mcilvainecompany.com.
while municipal water and wastewater will
account for 18 percent. The chemical indus-
try will generate sales of over $6 billion. The
forecast shows there will be a big market
for valves for basic chemical applications in
Asia, whereas the U.S. and Europe markets
will mostly be fine chemicals.
The movement toward “smart valves” is
accelerating, McIlvaine says, which allows
the condition of valves to be monitored
remotely. Actuators comprise up to 25
percent of the value market. Pneumatic,
electric and hydraulic actuators are avail-
able. Many of the large valve manufactur-
ers make their own actuators and also sell
actuators for competitors’ valves. A number
World Industrial Valve and

Actuator Revenues ($ Millions)
Industry 2013
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Porter Instrument Division. Now, the expanded line of P-Series acrylic,
Iron & Steel 2,341 glass and metal variable area meters provides even greater application
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Mining 1,114 and on-time delivery that Porter Instrument is known for.
Oil & Gas 9,246 Explore your options at PorterInstrument.com.
Other Electronics 359
Other Industries 6,301
Pharmaceutical 1,612
Power 7,555
Pulp & Paper 3,343
Refining 7,287
Wastewater 4,267
Water 3,619
Total 55,675
Source: McIlvaine Company

news & notes
trendlines
Mergers & Acquisitions

✓ Global pump manufacturer Grundfos (www.grundfos. a definitive asset purchase agreement to acquire Piper Valve
com) has acquired Enaqua, (www.enaqua.com) a California- Systems Ltd. Headquartered in Oklahoma City, Okla., Piper
based company specializing in the use of UV technology to dis- Valve Systems designs and manufactures high-pressure valves
infect water, and specialized membranes for water purification. and manifold components for the oil and gas industry.
✓ DeZURIK Inc., (www.dezurik.com) a supplier of munici- ✓ Furmanite Corporation (www.furmanite.com), a large

pal and industrial valves, has reached a definitive agreement to provider of valve services, has acquired certain assets and
acquire HILTON Valve Inc. (www.hiltonvalve.com), a supplier of operations of Crane Energy Flow Solutions’ Houston Service
fabricated large-diameter and custom knife gate valves. Under Center.
✓ Parker Hannifin Corporation (www.parker.com) has

terms of the agreement, DeZURIK will acquire all HILTON prod-
ucts and production capability. HILTON operations will continue
as a stand-alone business in the company’s present Redmond, acquired the filtration business of John Fowler (India) Private
Wash. facility. Limited based in Bangalore, India. The John Fowler filtration
✓ Kaman Industrial Technologies Corporation (KIT), a sub-

business manufactures air, fuel and hydraulic filters for use in
transportation and industrial applications.
✓ Fluid and metering technologies company IDEX

sidiary of Kaman Corporation (www.kaman.com), has acquired
Florida Bearings Inc. of Miami, Fla. Florida Bearings will become
part of KIT, Kaman’s Industrial Distribution segment. Corporation (www.idexcorp.com) has acquired Matcon Group
✓ Oil States Industries Inc., a subsidiary of Oil States

Ltd., (www.matconibc.com) a provider of material processing
solutions for high-value powders used in the manufacture of
International Inc. (www.oilstatesintl.com), has entered into pharmaceuticals, food, plastics, and fine chemicals.

trendlines
accountability file
Fieldbus Foundation Updates Specs for Remote
Operations Management •฀ The฀skyline฀copy฀on฀the฀June฀2012฀cover฀
teased฀“Industrial฀Cloud฀Computing,”฀how-
The฀Fieldbus฀Foundation฀(www.field including฀WirelessHART฀and฀ISA100.11a.฀ ever,฀the฀article฀on฀this฀topic฀did฀not฀appear฀
bus.org)฀has฀updated฀its฀FOUNDATION฀ It฀provides฀an฀interface฀to฀these฀wireless฀ in฀the฀June฀issue.฀It฀appeared฀in฀the฀July฀
technical฀specifications฀to฀address฀ technologies฀and฀uses฀Electronic฀Device฀ issue฀instead.฀We฀regret฀this฀error.
key฀elements฀of฀its฀FOUNDATION฀for฀ Description฀Language฀(EDDL)฀and฀func-
Remote฀Operations฀Management฀ tion฀blocks฀to฀ensure฀interoperability฀ •฀ The฀headline฀for฀the฀July฀2012฀
(ROM)฀technology,฀which฀is฀designed฀to฀ with฀FOUNDATION฀for฀ROM฀devices.฀The฀ Applications฀Note฀on฀page฀12฀should฀have฀
enable฀manufacturers฀to฀begin฀devel- Remote฀I/O฀(RIO)฀portion฀of฀the฀specifica- read฀Part฀III฀instead฀of฀Part฀ll.
oping฀FOUNDATION฀for฀ROM฀devices.฀ tion฀was฀released฀in฀April฀of฀last฀year฀
Specifications฀have฀also฀been฀added฀for฀ and฀allows฀for฀connectivity฀of฀large฀point฀ •฀ In฀the฀July฀2012฀News฀&฀Notes฀section,฀
transducer฀blocks฀for฀both฀wired฀and฀ count฀remote฀I/O฀to฀FOUNDATION฀field- page฀10,฀the฀second฀URL฀mentioned฀for฀Lux฀
WirelessHART฀devices. bus.฀The฀foundation฀recently฀announced฀ Research฀was฀incorrect.฀The฀correct฀URL฀is฀
The฀Fieldbus฀Foundation’s฀FOUNDATION฀ the฀launch฀of฀the฀HART฀and฀WirelessHART฀ www.luxresearchinc.com.฀Also฀on฀page฀10,฀
for฀ROM฀solution฀offers฀a฀unified฀digital฀ specification฀for฀ROM. the฀first฀URL฀given฀for฀the฀Control฀System฀
infrastructure฀for฀asset฀management฀in฀a฀ Fieldbus฀Foundation฀members฀with฀ Integrators฀Association฀(CSIA)฀was฀incorrect.฀
range฀of฀remote฀applications,฀from฀oil฀and฀ up-to-date฀license฀agreements฀can฀ The฀correct฀URL฀is฀www.controlsys.org.
gas฀pipelines฀to฀tank฀farms฀and฀offshore฀ download฀a฀complete฀copy฀of฀the฀latest฀
platforms,฀and฀also฀OEM฀skid-mounted฀ FOUNDATION฀fieldbus฀technical฀speci- Help us make Flow Control the best it can be!
equipment.฀The฀technology฀enables฀ fications฀from฀Fieldbus฀Forums฀on฀the฀ If you see any errors, mix-ups, or oversights,
fieldbus฀connectivity฀to฀remote฀I/O฀and฀ foundation’s฀End฀User฀Resources฀section฀ whether grammatical or technical, please
the฀leading฀industrial฀wireless฀protocols,฀ of฀its฀website฀www.fieldbus.org. e-mail [email protected].
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www.FlowControlNetwork.com฀ August฀2012฀฀฀11฀฀
applications corner
By David W. Spitzer
Part I: Variable-Speed Drive Energy Savings

How misapplication of the Affinity Laws can lead to over-estimates
I
nstalling variable-speed drives can yield significant electrical
energy savings. Every few years, I am asked to review a paper The operation of centrifugal equipment with
citing the energy savings that can be obtained in pumping
applications where the author uses the Affinity Laws to incor- variable-speed drives can provide signifi-
rectly calculate electrical energy savings when applying a
variable-speed drive. However, misapplication of the Affinity Laws cant energy savings that can often justify
can result in over-estimates of the energy savings (sometimes
grossly) associated with operating the pump with a variable- the investment for both new and retrofit
speed drive. Let me explain.
applications. Consideration should be given
✓ Flowrate is proportional to the pump motor speed;
The Affinity Laws for centrifugal pumps state that the pump’s:
✓ Pressure generated is proportional to the square of the to applying them to the majority of pumps
✓ Motor power consumption (kW) is proportional to the cube
pump motor speed; and that are used in continuous operations.
of the pump motor speed. However, the Affinity Laws can seem
The operation of centrifugal equipment with variable-speed drives relatively simple and straightforward—
can provide significant energy savings that can often justify the
investment for both new and retrofit applications. Consideration maybe too straightforward.
should be given to applying them to the majority of pumps that
are used in continuous operations. However, the Affinity Laws can
seem relatively simple and straightforward—maybe too straight-
forward. For example, consider a piping system where a motor/
pump produces 100 percent flow at a pressure of 10 meters of
water column. It would seem logical to calculate the energy sav-
✓ 50 percent of flow means that the motor/pump operates at

ings at 50 percent of flow as follows:
✓ Power consumption is (0.50)3 or 12.5 percent of the power

50 percent of speed (per the first Affinity Law);
✓ There is an 87.5 percent energy savings when operating the

at 100 percent flow (per the third Affinity Law); and
Flow Problems? motor/pump with a variable-speed drive at 50 percent of flow.
We Can Help WRONG!!! Give it some thought until next month. FC
David W. Spitzer is a regular contributor to Flow Control maga-

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Mr. Spitzer can be reached at 845 623-1830 or
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www.spitzerandboyes.com • 1.845.623.1830 measurement technologies.

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installation guidelines
Do Your Thermowells Meet the ASME Standard?

Thermowell design has become more conservative in the age of ASME/ANSI 19.3TW-2010
T
hermowells are universally used in pipe and call it a day? This is primarily due to the fact that only
power, chemical, hydrocarbon In many cases the middle one-third of the system designer has all the knowledge
and other industries. In 2010, the the pipe may be a perfectly good rule of and details about the process conditions
only U.S. standard assessing the design thumb. However, depending on process and installation arrangement required for
strength of thermowells was significantly conditions there are a number of other fac- the thermowell design. The thermowell
changed for the first time in 35 years. tors that can cause a thermowell to suffer supplier only knows what the system
mechanical failure at insertion lengths less designer tells him.
Thermowell Fundamentals than one-third of the pipe. These include What could be simpler than a thermowell?
What could be simpler than a thermowell? flow-induced vibration (wake frequency The devil, as they say, is in the details.
Thermowells are metal products machined failure), dynamic (oscillating) and steady
and gun-drilled from solid bar stock to state stress, pressure, corrosion, erosion, What is a Thermowell for
encase a temperature sensor such as a material selection, and improper installation Purposes of the ASME 19.3TW
thermocouple or RTD. They are typically technique. All of these must be considered Standard?
welded into place or attached to a pro- in properly designing a thermowell for a Before plunging into the details of ther-
cess by means of a flanged or threaded given installation. mowell design it is important to have a
connection. There are three primary ther- So who is responsible for making the good grasp of the fundamentals. Here is
judgment call here? The 19.3TW standard an easy question: What is a thermowell?
makes plain that ultimate design respon- Remember the old saying: if it looks like
sibility for a thermowell well rests with the a duck, walks like a duck and quacks like
engineer designing the system into which a duck, it is a duck? Thermowells are not
the well is being installed: ducks. There are many instances where
Specification of a thermowell, includ- something may look like a thermowell
ing details of its intended installation and without falling within the design criteria for
all intended operating conditions, is the the 19.3TW Thermowells standard.
responsibility of the designer of the sys- For example, the relatively subtle dis-
tem that incorporates the thermowell. The tinction between protection tubes and
designer of that system is also responsible thermowells is an important one. There
for ensuring the thermowell is compat- are no welds in a thermowell, except for
ible with the process fluid and with the a weld necessary to attach a flange to the
design of the thermowell installation in the thermowell shank. By contrast, protection
system. tubes are commonly manufactured from
Various thermowell process connections and

shank styles are shown here. The ASME Code
treats each one differently.
mowell shank styles. Conveniently, each

of these is rather straightforwardly titled:
straight, tapered and stepped. The core
function of a thermowell is to enable the
removal and replacement of a temperature
sensor without opening up the process.
Designing a thermowell seems simple.
The thermowell just needs to protrude far
enough into the process fluid flow to allow
the temperature sensor to reach the tem-
perature of the process in a reasonable
amount of time. Why not simply design the
Typical flanged thermowell. No welds save for flange attachment.
well to reach the middle one-third of the

By Mitchell P. Johnson, J.D. & Allan G. Gilson, P.E.
metal pipe with a tip welded onto the end. plain old solid bar stock thermowells can resulting document established a simple
Protection tubes are also commonly used be outside the scope of the standard if four-page calculation yielding a pass-fail
in power, chemical, hydrocarbon and other they do not meet specific dimensional cri- result for steam line thermowells.1 The
industrial temperature measurement appli- teria. This does not mean that any of these location of the requirements was some-
cations, often in low-velocity gas applica- arrangements is necessarily bad. It simply what unique since they were included in
tions. Sometimes protection tubes are means that their design is outside the a code for testing rather than a code for
even casually referred to as “wells,” but scope of the standard. Hence, any calcula- design (such as Boiler and Pressure Vessel
their design falls squarely outside the type tion results from 19.3TW may not be valid. Code or Power Piping).
covered under the scope of the 19.3TW In other words, the calculation results will Due to the standard’s unique status and
standard. They are welded and there is no not assure that the nonconforming ther- simple approach, over the years 19.3 was
weld in a thermowell. mowell can withstand the damage effects commonly used outside its original intended
The 19.3TW standard modernized 19.3TW seeks to guard against. scope across a broad range of applications
thermowell evaluation considerably by and industries. This was unintentionally
adopting modern bore sizes and shank History Prompting the Change enabled in part by limitations and ambigui-
constructions. However, there are a num- From the ASME 19.3 to 19.3TW- ties contained in the standard itself.
ber of common thermowell designs that 2010 Method Despite broad implementation by engi-
are outside the scope of the standard. For So how did we end up with a thermowell neering firms, field failures of thermowells
example, thermowells outside the scope standard in the first place? cropped up and persisted on an intermit-
include those that are shot-peened, coat- The intent of the original drafters of tent basis in non-steam applications even
ed, sleeve, or flame sprayed. Thermowells the 19.3 standard in 1974 was to create among thermowells assessed by and
with velocity collars, external support or requirements for Power Test Code applica- built to the 19.3 standard. Among many
welds at any point other than a flange tions to prevent steam turbine-damaging noted thermowell failures, perhaps the
attachment are also excluded. Finally, even thermowell failures in steam lines. The most famous involved a sodium line at the
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✓ Provided no fatigue factor for oscillatory stress or stress

state bending stresses,
✓ Performed the installed natural frequency calculation in a

intensification factor for fatigue at the thermowell root, and
crude manner without including any effects of foundation stiff-

ness, fluid or sensor mass.
Some publications4 and even standards5 actually referenced
the 19.3 standard and then, not trusting its result, handicapped
it. The opportunity for improvement was clearly identified.6
After approximately five years of work, in July 2010, the ASME
PTC 19.3TW (2010) standard was published and received ANSI
approval.
What Changed in 19.3TW & Why It Is So Much

More Conservative Than 19.3
In most applications, 19.3TW is significantly more conservative
In-line forces were not considered by the 19.3 until the 19.3TW-2010 than its predecessor, resulting in maximum allowable thermowell
revision. Previous versions only took transverse resonance into account. immersion lengths much shorter than previously allowed under
the old 19.3 regime. This consideration is primarily due to con-
Japanese MONJU nuclear reactor where a catastrophic thermow- sideration of in-line resonance and oscillating (dynamic) stress.
ell failure resulted in a liquid sodium line leak. In a small minority of cases primarily involving low-density gases
Prior to the MONJU failure, engineering2 and academic3 criti- where viscosity values are available 19.3TW may actually permit
cisms of the old standard pointed out, among other concerns, that longer immersion lengths due to its ability to tailor the Strouhal
✓ Failed to address in-line vibration,

the ASME PTC 19.3: number to a particular application, instead of relying upon a
✓ Failed to assess oscillatory stress independent of steady

default value.
Other changes include accommodating modern geometries,
step-shanks, an unlimited velocity range, a predicted life cycle,
rules regarding manufacturing tolerances, dimensional limita-
tions and consideration of corrosion and erosion factors. For the
first time, 19.3TW made clear that support structures such as
velocity support collars are ill-advised and outside the scope of
the standard,7 primarily due to impracticalities regarding their
manufacturing and installation. For the first time 19.3TW recog-
nized that all thermowells are not equal in terms of their rigidity
and susceptibility to vibration. Values such as the sensor mass,
fluid mass and process connection design are for the first time
incorporated into the calculation of the installed natural frequency
of the thermowell.
However, for all of the modifications to the form and substance
of 19.3 in 19.3TW, by far the most significant factor impacting
thermowell design is the recognition of the need to avoid in-line
resonance in most cases—the factor identified as the root cause
of the MONJU failure.
Both in-line and transverse resonance are forms of wake
frequency resonance. As process fluid passes a thermowell
shank vortices are created in its wake and the thermowell stem
vibrates.
When the thermowell vibration approaches the frequency of the
shed vortices, the amplitude of vibration increases dramatically.
This exerts tremendous force and stress against the thermowell's
base. In many cases this stress is fully capable of causing the
thermowell material to fracture or even shear off at the point of
greatest stress, the thermowell root.
The 19.3 standard conceived of thermowell vibration as occur-
ring in a single plane transverse to the flow. Resonance was

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judged as possible whenever the wake frequency approached thermowell designer prior to the publication of 19.3. The setting
80 percent of the natural frequency of the installed well. Indeed, is a large circulating water line with thermowells installed on
transverse vibration is a real danger and its occurrence should be the outside elbow of the pipe. Thermowells are designed based
avoided if possible as it can be catastrophic for the well. However, upon traditionally successful engineering in-house standard and
a thermowell does not vibrate in a single plane. In reality the ther- installed on the outside of the water line following an elbow.
mowell vibrates in an oscillating fashion that includes an in-line A month following the installation the gauge installed in
component. The in-line component can begin to resonate with the well is found to be leaking water by operators. The well is
the shed vortices at wake frequencies spanning 40 percent to 60 removed and is discovered to have failed. Because the shank of
percent of the installed natural frequency of the well. the well is missing entirely, the
Recognition and avoidance of dangers posed by in-line reso- operators at first suspect that
nance is critical to proper thermowell design, but the practical a ceramic well has been pro-
effect of reducing the wake to natural frequency limit from vided by accident.
0.8 to 0.4 can be very significant. The danger of ther-
First catastrophic well failure
mowell resonance must be considered at velocities much
caused by wake frequency
lower than previously considered problematic by 19.3. vibration. Root cause: supplier
Since process fluid speeds will not slow to accom- not providing well as specified.
modate the ideal length of a thermowell, the effect is a
reduction in the maximum allowable unsupported lengths A root cause analysis is per-
for many thermowells. This reduction challenges engineers formed and wake frequency calcula-
involved in design of thermowell applications to update their tions per the original 19.3 requirements
standards to reflect appropriate immersion lengths based upon are performed providing velocity values calculated
a more conservative mechanical standard or to bulk up their from the maximum flowing condition, based on pump run-out.
thermowells to enable a sufficient immersion length. As a result, The thermowell passes muster under the calculation. Because
engineers applying the 19.3TW standard can now be more con- the investigating engineer is on the 19.3TW committee, the then-
fident in their thermowell installation integrity. For every give, unpublished 19.3TW calculation is applied to the incident. The
however, there is a take and the complexity of the calculation well also passes muster under 19.3TW. The thermowell design
required to assess thermowell designs has greatly increased. itself is examined and it is found that the manufacturer supplied
Supplier-generated thermowell design software applying an “off-the-shelf” thermowell instead of the specified design.
the 19.3TW standard such as SwiftyCalc (www.jms-se.com/ An order is issued for a replacement well. Proper manufacture
SwiftyCalc) is helpful, but like everything else in order to reap is confirmed and the well is re-installed. A few weeks later the
a full benefit it is helpful to have a fundamental understanding operators call back. The well has failed again!
of how and why the standard works the way that it does. The This time the velocity value is questioned and a computational
19.3TW standard provides two example calculations that can be fluid dynamic (CFD) model is performed. The model shows that
used to validate the software results. actual velocity at the well location is approximately twice what
had been designed for based on pump run out.
But Does the 19.3TW Really Work? The CFD model demonstrated how the fluid flow stratified signifi-
The Proof Of the Pudding Is In the Tasting. cantly along the backside of the elbow, resulting in a much higher
So here is a quick tale of two wells in a common trap for the velocity than the average. Wake frequency calculations were then
performed again using the new predicted velocity and pursuant to
Approximate
Location of failed
thermowell
CFD print-out showing a plan view of the piping. Fluid velocity is shown in
Typical thermowell installation on outside elbow of circulating water line. color with the highest fluid velocity in dark red.

the old 19.3 method. Surprisingly, the well design passes muster variety of energy and oil/gas projects. He is a member of
under 19.3, but 19.3TW accurately predicts the failure. ISA and ASME, and currently serves on the PTC 19.3 Temperature
A new well is designed and manufactured in conformance with Measurement committee. He has authored and co-authored a
19.3TW. Essentially, the well is shortened 4 inches and a quarter- number of presentations and technical articles on thermowells,
inch of mass is added to the root diameter. Following the third process tubing, and other subjects, including “The New ASME
installation, the well has been in place for years without report of Thermowell Standard and Optimal Thermowell Design,” 2011. He
incident. can be reached at [email protected].
References
1. ASME/ANSI 19.3 “Temperature Measurement” (2004).
2. Gibson, I.H., “Optimal Selection of Thermowells”, ISA
Transactions 34 (1995).
3. Brock, J.E., 1974, “Stress Analysis of Thermowells”, Report
NPS-59B074112A, Naval Postgraduate School, Monterey, CA.
4. See e.g., Gibson, I.H., “Optimal Selection of Thermowells”,
ISA Transactions 34 (1995) 209-216(establishing 70%, not 80%
established by 19.3, as the controlling ratio between natural fre-
Location of quency and wake frequency).
thermowell tip 5. See e.g.,“Process Measurement Instrumentation”, API
Recommended Practice 551, Sec. 5.2.3 (2007) (establishing 66
percent, not 80 percent established by 19.3, as the controlling
CFD print-out showing pipe cross section. Dark red indicates the area of ratio between natural frequency and wake frequency).
highest velocity.
6. Bartran, D.S., Frikken, D.R., Yee, R., “Are Your Thermowells
Safe?” TAPPI Journal, April 2002.
Challenges Ahead 7. ASME/ANSI 19.3TW-2010, Tables 4-1-1 and 4-2-1..
Engineers seeking an optimal thermowell design face a sig-
nificant challenge. Temperature measurement considerations
indicate that the longer and leaner the thermowell, the more
accurate and responsive will be the installed temperature sensor.
Conversely, considerations promoting mechanical strength dictate
as short and stout a design as possible. For more than 35 years
engineers around the world have relied upon the ASME 19.3
standard. Now the new 19.3TW standard will help better navigate
a solution to these opposing design considerations.
Engineers involved in the design, specification and procure-
ment of thermowells should familiarize themselves and refresh
their engineering standard to comply with the 19.3TW standard. Outstanding Flow
In the course of doing so, alliance with a knowledgeable vendor
or an experienced engineering consultant can be the key to Sensor Solutions
avoiding incidents resulting from thermowell failure ranging from
the mildly annoying to catastrophic. FC
Featuring the MFS02
Mitch Johnson, J.D. is the president of JMS Southeast (www. micro low sensor:
jms-se.com), a manufacturer of custom temperature sensors • 0 to 50m/s low range 5 mm
and thermowells based in Statesville, N.C. Mr. Johnson is a • 0.001m/s sensitivity
member of the ISA and serves on the ASTM E20 Committee,
the ASME 19.3TW, 19.3 and 40.9 Committees. Recently, he co-
• < 10ms response time
authored “Practical Thermocouple Thermometry” (2nd Ed.), and • Flow direction indicated
was named a “Control Engineering Leader Under 40.” He can be 3.5 mm
reached at [email protected].
Allan Gilson, PE, is the Instrumentation and Control Section

Head for Black & Veatch Energy (www.bv.com), headquartered in TEMPERATURE HUMIDITY FLOW
Overland Park, Kan. He provides process management and con-
sulting for Instrumentation and Control engineering practices for a www.ist-usadivision.com

best practices
Establishing a Mechanical Seal Baseline

Calculation method for Plan 23 systems in hot water service
O
il refineries began using the precursor to API Plan 23 to seal
Nomenclature & Units Of Measure
light hydrocarbons that had to be cooled to prevent flash-
A Area, m2 Q Volumetric flow rate, L/s
ing and short mechanical seal life. Circulating devices were
Cp Specific heat, J/kg-°C q Heat transfer, W
added to the seal design to circulate the process fluid through a
d Diameter, m ReReynolds number
shell and tube heat exchanger in a nearly closed loop. Decades
e Absolute roughness, m T Temperature, °C
later, API Plan 23 has proven to be the most effective way of seal-
f Friction factor t Thickness, mm
ing hot fluids in centrifugal pumps from a reliability, safety and
g Gravitational constant, m/s2 U Overall heat transfer
economic perspective. These systems, extended from refining to
H Head, m coefficient, W/m2-°C
power generation, are used widely today in water applications
L Length, mm v Velocity, m/s
above 80 C, such as boiler feedwater services.
M Mass flow rate, kg/s μ Dynamic viscosity, kg/m-s
Detailed design calculations are not required in most cases where
m Heat soak factor (same as Pa-s)
the application is a typical Plan 23, the mechanical seal contains
P Pressure, kPa ρ Density, kg/m3
a well designed circulating device, best practices are used for the
layout and piping of the loop, and a well designed heat exchanger The method introduced here is iterative. This is due to:
with known performance characteristics is used. But in some cases 1. The use of the log mean temperature difference (LMTD)
where one or more of these parameters is unusual, the application is used in determining heat exchange rate,
hazardous, plant critical, or a due diligence study is advisable, then 2. The determination of the mass flowrate of the recirculated
predictive calculations can be performed. process fluid as a function of friction losses,
3. Some parameters are nonlinear functions, such as:
a. Absolute viscosity as a function of temperature
(exponential curve fit),
b. Friction losses (empirical),
c. Head-versus-flow function of the circulating device
(curve fit).
In order to achieve accuracy, the following input parameters are
required:
1. The operating temperature of the process fluid,
2. Liquid density and viscosity as functions of temperature,
3. Dimensionless factors m1 through m6, as defined by Buck
and Chen (2010),
4. The head-versus-flow curve for the circulating device in the
mechanical seal,
5. Several dimensions of the seal cooler and interconnecting
piping,
6. The flowrate and temperature of the cooling fluid entering
the seal cooler,
7. Mechanical seal generated heat.
Figure 1. Plan 23 systems installed on a high-pressure multistage pump At the end of this article, some rule-of-thumb values for quick
“back of the envelope” calculations will be included. These are
These calculations can be used as a baseline to determine valuable when one does not have a detailed description of the
if the mechanical seal is leaking, the Plan 23 tubing has been mechanical seal, the seal cooler or pump construction.
clogged or fouled, or the cooling water supply is insufficient. In
each case, one will see a rise in the Plan 23 loop temperatures The Physical System of a Plan 23
over time. If the performance parameters are measured in the The calculations in this method are based on a shell and tube
field, this algorithm can be altered empirically for further com- cooler wherein the process fluid flows through the tube side, and
parison. Altering the overall heat-transfer coefficient is usually the the cooling liquid flows through the shell side (Figure 1). (One can
best way to do this. easily modify these calculations for other cooler configurations.)

By John Merrill
Plan 23 systems
for Drive End and perature. Density of a liquid is a nearly linear function of tempera-
Non-Drive End ture. The density change across the cooler and the mechanical
Seals seal can be 1-5 percent (particularly within the iteration steps), so
this function must be included on the hot side of the Plan 23 loop.
Graphic courtesy
So, the two terms are modeled as:
of KSB (ksb.com)
! ! = !" ! !! + !! Eq. (3)
Plan 23 Loop Flowrate
We will need a Plan 23 mass flowrate, Mhot, in order to calculate ! ! = !! ! + !! Eq. (4)
the rate of heat transfer, qcooler. This flowrate is generated by the
circulating device in the mechanical seal. There are two basic For clean water, these terms are:
types of circulating devices used for mechanical seals: radial !! = −4.7! − 4, !! = 0.0024, !! = 1009, !! = −0
circulating rings and positive-displacement pumping screws.
!! =
Each has a characteristic −4.7!
curve − 4, below.!A! radial
as shown = 0.0024,
circulat- !! = 1009, !! = −0.441
ing ring curve can be approximated by a second order curve as (These constants must be consistent with the units specified
shown. A pumping screw curve is linear, as can be expected from above.)
a positive-displacement device.
The flow velocity for a flow Q: The average temperature of the liquid in the Plan 23 loop, T, will
be an iterative value as shown later.
!! !! !" !
0.001 Eq. (1) !" = Eq. (5)
!=! ! ! !
!!"#$ !" < 2100 !"#$%"& !"#$
Where: !" ≥ 2100 !"#$"%&'! !"#$
!
!!"#$ = !!! Eq. (2) Reynolds numbers can range from 1,000 to 6,000 when the
4
Plan 23 flow is on the shell side of the cooler, so the laminar or
The Reynolds number is calculated to determine if the flowrate is turbulent check is important. The friction factor f is calculated
laminar or turbulent. The Reynolds number equation contains the as follows. A slight discontinuity will exist at Re = 2,100. Friction
viscosity term, μ, and the density term, ρ. The viscosity of nearly factor relationships that can model the entire laminar-transition-
all liquids can be characterized as an exponential function of tem- turbulent range exist but are very difficult to evaluate, and the
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best practices
increase in accuracy and continuity do not justify their use.1 Hf is equal to Hscrew. Setting these two relations equal to one
64 another gives
!!"#$%"& = Eq. (6)
!" !!" ! ! !!!"#$
= !! + !! = 1000!!!"#$ !! + !!
!! 2! !!
0.001
!
0.25 Eq. (7)
!!"#$"%&'! = ! This can be arranged as a quadratic equation with v as the vari-
! 5.74 able and the other terms constants:
!"#!" 3.7!! + !" !.! !!"
! ! + −1000!!!"#$ !! ! + −!! = 0 Eq. (12)
!! 2!
The dimensionless friction factors, k, can be determined.
Which has the solution:
!
!!"#$ =!
!! ! 2!!"
1000!!"#$ !! ± 1000!!"#$ !! + !
!! ! ! Eq. (13)
!!"#$%"&! = 1.0!!"
!=
!!"
!!"#$ = 0.78!!" !! !
!!!"$ = 0.6!!"#$ Which will produce a positive and negative value of v, and we
select the positive one. Finally, the mass flowrate, M, can be
Where n is the number of entrances or exits in the system loop. determined.
There will be two of each: in and out of the seal; in and out of the Eq. (14)
!!!" = !"!!"#$
cooler. One can add k factors for other resistive causes, such as
tees, elbows, valves, but since these devices are not recommended, The mass flowrate of the cooling fluid is calculated. Since the
they are ignored. The overall friction factor ktotal is the sum of all k’s. flowrate of the cooling fluid is assumed to be constant and rela-
tively high (0.5 to 1.25 L/s), and the temperature rise through the
!!"!#$ = !!"#$ + !!"#$%"&! + !!"#$ + !!"#$ Eq. (8) cooler should not be greater than about 10 Δ°C, the change in
density will be less than 1 percent and can be considered con-
The equivalent length of the piping system is stant.
!!
!! Eq. (9) !!"#$ = !!"#$ !!"#$ 0.001
!!" = !!"!#$ !
!
And now the head loss Hf can be calculated for any flow velocity v. The Heat Transfer System
There are two main sources of heat flowing into the Plan 23
!!" ! ! process liquid—heat soak, qsoak, and seal generated heat, qseal.
!! = Eq. (10)
!! 2! There is one significant source of heat removal—the seal cooler,
qcooler. If these sources are at steady state then the heat transfer
A pumping screw device in a mechanical seal will have a linear balance equation is:
head versus flow relationship of the form:
!!"#$ + !!"#$ − !!""#$% = 0
!!"#$% = !! !!"#$% + !! Eq. (11)
From Buck and Chen (2010)2, heat soak may be calculated as
where a1 and a0 are constants specific to the screw dimensions, follows:
fluid and speed. The flow generated by the pumping screw Qscrew
!!"#$ = !! !! !! !! !! !! !"!! !" Eq. (16)
will enter the interconnecting Plan 23 tubing, which has a flow
area Aflow, calculated above. Where m1 through m6 are the dimensionless factors used to cor-
rect the equation recommended by API 682, which recommends
!!!"#$ a singular UA value of:
!!"#$% =
!! !" = 249 W/m-°C
0.001
!
Substituting this into the pumping screw relation !! = seal balance diameter, m
!!!"#$ And:
!!"#$% = !! + !!
!! !" = !!!"!$%% − !!!!
0.001
! Where Tprocess is the process liquid bulk temperature in the pump
The flow velocity through the Plan 23 tubing will be that at which casing and Tchm is the average bulk temperature in the seal

chamber. If the pump has a cooling jacket in front of the seal, it is Solution Example
acceptable to use qsoak = 0. Inputs: Outputs:
The seal generated heat, qseal, can be calculated using the Plan 23 loop and cooling fluid = water Qhot = 0.09 L/s
method recommended by API 682 or obtained from the mechani- dB = 100 mm qsoak = 3058 W
cal seal manufacturer. The heat transfer occurring across the heat qseal = 1500 W qcooler = 4561 W
exchanger can be calculated three ways, all of which are required Qcold = 0.75 L/s Th1 = 46.3°C
in this method. Tc1 = 25°C Th2 = 58.8 °C
!!""#$% = !!!" !!,!!" !"!!" Eq. (17) Tprocess = 150 °C Tc2 = 26.5 °C
!!""#$% = !!"#$ !!,!"#$ !"!"#$ Eq. (18) Quick Calculations

The following values and calculations can be used for simple
!!""#$% = !!""#$% !!" !"!" Eq. (19) hot process water analysis where many of the detailed variables
above are unknown. This method is useful for troubleshooting
In these three equations, the subscripts hot and cold refer to the applications in the field or sizing heat exchangers or cooling
side of the heat exchanger containing the process fluid and the water requirements for budgetary proposals:
side containing the cooling liquid, respectively. The dT values are
!"
calculated as follows: !!!" = 0.001 · seal size, mm
! · !!
!"!!" = !!! − !!! !"
!!"#$ = 0.75
!"!"#$ = !!! − !!! !
!!""#$% = 3000 · !!"#$ · 2°C )answer in Watts
!!! − !!! − !!! − !!! Eq. (20)
!"!" = !!""#$%
! − !!! !"!!" = )answer in °C
!" !! 3000 · !!!"
!!! − !!!
The log mean area is used because the U value used for the heat The actual loop temperatures, Th1 and Th2, will be functions of
exchanger is an overall heat transfer coefficient defined neither seal generated heat and heat soak (neither of which are measur-
by the OD nor the ID of the tubes: able in the field) but should each be between 30 C and 50 C, and
!! − ! ! the dThot should be between 2 and 4 Δ°C.
!!" = Eq. (21) The results of the quick calculations are:
!
!" !! !"
! !!!" = 0.1
!
Where: !!""#$% = 4500 !
! !
!! = ! !!! and !! = ! !!! !"!!" = 15 °!
The overall heat transfer coefficient, Ucooler, can be calculated John Merrill is the U.S. Principal Engineer for EagleBurgmann,
using several different empirical formulas, but one can obtain a manufacturer of mechanical seals and sealing solutions. Mr.
good accuracy by using curve fit functions or singular values Merrill has been designing, installing, troubleshooting, and test-
obtained through testing. (520 W/m2-°C is a reliable value to use ing mechanical face seals and seal support systems since 1991.
for modern seal coolers supplied by seal manufacturers.) His market sector experience includes upstream and downstream
Now we have the system of equations that govern the Plan oil and gas, mining, chemical production, biopharmaceuticals,
23 flow and heat transfer relationships. Unfortunately we cannot fossil and nuclear power generation. Mr. Merrill currently serves
solve for the unknown temperatures Th1, Th2 and Tc2 because of as chairman of the Hydraulic Institute’s Seals Committee and par-
the nonlinear log mean temperature equation for dTLM. We cannot ticipates in the Reliability Committee. He can be reached at john.
solve directly for the mass flowrate through the system because [email protected] or 704 525-9672.
the viscosity and density terms in the Reynolds equation are
functions of the unknown temperatures and the nonlinear expres- www.eagleburgmann.com
sion for the friction factor fturbulent used if the flow is in the turbu-
lent regime. But several methods of solving a system of nonlinear References
equations exist. Most methods use a convergence criterion, which 1. See McKeon, B.J., C.J. Swanson, M.V. Zaragola, R.J. Donnelley,
defines when a solution has been found. For our problem, one and A.J. Smits. "Friction Factors for Smooth Pipe Flow." J. Fluid
could keep guessing at Th1 until Eq. (15) has been satisfied to Mech. 511 (2004): 41-44.
within 0.5 percent or so. Using the Solver function in Microsoft 2. Buck, Gordon S., and Tsu Yen Chen. An Improved Heat Soak
Excel is one of the easiest ways to solve this system of equations Calculation for Mechanical Seals. Proc. of Proceedings of the 26th
(see “Solution Example” sidebar). International Pump Users Symposium, Houston, TX, 2010.

focus on: temperature measurement
FREE PRODUCT INFO: For FREE PRODUCT INFO, write in the numbers listed with each product in the FREE INFORMATION section of the
reader service card bound in this issue of the magazine, or visit www.FlowControlNetwork.com/freeinfo.
Combo Pressure/Temperature
Sensors
American Sensor Technologies’
Model AST20PT Stainless Steel Media
Isolated Pressure/Temperature Sensor
and Model AST46PT Explosion-proof
Pressure/Temperature Transmitter
provide both pressure and temperature
outputs from a single process point.
This dual output configuration is
designed to reduce process penetration
points and leaks in critical systems such
as hydrogen, oxygen, heavy oil processing, hydraulics, analyzers, offshore, pipelines, Miniature Temperature Transmitter
and ammonia systems. They also are a good fit for low-power systems as both a pres- for Process Control
sure and temperature reading are generated with the power consumption of one sen- Omega’s TX-M12 Series of miniature
sor. Incorporating a microprocessor-controlled design, along with AST’s one-piece body temperature transmitters are a new range
construction, both the Model AST20PT Sensor and Model AST46PT Transmitter offer (-200 to 850 C and -328 to 1862 F) offer-
high-accuracy pressure and temperature measurements of +/-0.1 percent and 1.0 per- ing improved performance over conven-
cent BFSL, respectively. Both units are available in various temperature ranges from -40 tional in-head devices. Housed in a rugged
to 250 F (-40 to 125C). The Model AST46PT is offered in pressure ranges up to 20,000 stainless steel enclosure, they are designed
PSI (1,400 bar), and the Model AST20PT is available in pressure ranges up to 45,000 PSI to provide fast, secure and watertight
(3,100 bar). FREE PRODUCT INFO: WRITE IN 100 | www.astsensors.com connections for both the sensor and the
instrumentation. At a fraction of the size
Thermocouple Virtual Chart of standard head-mounted transmitters,
Recorder measuring 38mm diameter with a height of
NEWPORT Electronics’ iTCX transmitter 20mm and weighing just 100 grams, they
monitors temperature from two inde- are a good fit for a range of applications
pendent thermocouple channels over an including process control and monitoring
Ethernet network or the Internet with no equipment. Omega’s miniature tempera-
special software except a Web browser. ture transmitter can accept a variety of
The transmitter serves Active Web Pages resistance sensors, including Pt100, Pt500,
to display real-time readings, tempera- Pt1000, Ni100, Ni1000, and variable resis-
ture charts, or log data in standard data tance up to 10,000 ohms. The integral M12
formats for use in a spreadsheet or data connectors maintain IP67 protection, while
acquisition program such as Excel or allowing for a quick and simple change
Visual Basic. The virtual chart viewed on of sensor. Two outputs are available with
the Web page is a JAVA Applet that plots either 4-20mA or 0-10Vdc with an accu-
a chart over the LAN or Internet in real racy of +/-0.2 C + 0.05 percent of reading.
time. The iTCX transmitters can take Thermocouple Types J, K, T, E, R, S, B, C, N, and L Default scaling for the output is 0 to 100
measuring temperatures up to 1,820 C (3,308 F). The iTCX can display and chart absolute C, and other ranges can be specified at the
measurements in two locations and a differential measurement between the two locations. time of purchase. FREE PRODUCT INFO:
FREE PRODUCT INFO: WRITE IN 101 | www.newportus.com WRITE IN 102 | www.omega.com
Remote Reading Thermometer

Dwyer Instruments’ Series RRT3 Remote Reading Thermometer with Switch combines
a 3¼-inch dual-scale dial thermometer and a SPDT relay. Color-coordinated point-
ers display the current process temperature and set point. In order to change the set
point, a front adjustment knob controls the red set point pointer. The design of the
internal mechanical switch movement prevents the set point pointer from sticking to the
process-indicating pointer. A 10.5-ft (3.2 m) stainless steel flex hose capillary prevents
kinking and leaking of the measuring fluid when bending the capillary. For quick installa-
tion, electrical connections can be made to male quick-connects or to the finger-safe screw terminals. Thermometer includes a
u-clamp mounting bracket for panel mounting. FREE PRODUCT INFO: WRITE IN 103 | www.dwyer-inst.com
September 29 – October 3, 2012
New Orleans Morial Convention Center
New Orleans, Louisiana
Customize
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technology spotlight
Gaining New Ground

Reference recorders shake things up in pressure measurement
W
ithin the pressure measurement industry, relentless inno- from a chart recorder in the field. Communicating or storing
vation has become the norm. New technology continu- this data electronically becomes possible only after a technician
ally supplants the old. In other technology spheres, PCs enters or scans the chart into a computer. This process typically
pushed aside typewriters. Cell phones drove out telephones. And takes several days before results become available. Chart record-
today, reference recorders are shaking up old standards in the oil ers typically claim an accuracy ranging from 0.25 percent to 1
& gas industry. percent of span, but that figure depends on changes in ambient
A reference recorder is a new class of instrument that is gain- temperature and on the thickness of its pens—which can cause
ing ground over other common pressure instruments. Chart an additional error up to 1 percent of the recorded reading.
recorders, deadweight testers, and analog pressure gauges all By contrast, a reference recorder exports digital data and records
brought several advantages in their time. Increasingly, reference with higher accuracy. Many reference recorders are also rated
recorders replace all three with a single instrument. Intrinsically Safe for use in the presence of flammable materials.
What Is a Reference Recorder? Using Deadweight Testers in the Field

Reference recorders unify the recording capability of a chart Deadweight testers are used primarily in a laboratory setting.
recorder, the high accuracy of a deadweight tester, and the con- They produce a repeatable reference pressure by balancing cali-
tinuous measurements of a pressure gauge into one tool that is brated masses on a piston of known area. Operators must use a
easier to use and less expensive. different set of masses for each engineering unit (i.e., one set of
“On their own, none of these features are unique, but when you weights for PSI, another for kPa). In an indoor, temperature-reg-
put them all in the same device and make it cost-effective, you end ulated environment, deadweight testers can be very accurate—
up with something really useful,” says Jim Pronge, sales manager serving as a primary standard for the calibration of other pressure
for Crystal Engineering (www.crystalengineering.net), a San Luis measurement devices. Field versions also exist but, outside the
Obispo, Calif.-based company that produces reference recorders lab, their accuracy depends on a host of factors.
and pressure gauges. “Offering reference recorders for both labora- In order to deliver an accurate reading, a field deadweight
tory and field applications is really the icing on the cake for us.” tester must be perfectly level. Additionally, ambient temperature,
While data logging devices are nothing new, Pronge points out humidity, wind, and local gravity will all impact the reading.
that, “improved microprocessors allow today’s reference record- Without adjusting for these, a field deadweight tester’s accuracy
ers to read and record faster and more accurately than ever.” may be no better than a common pressure gauge. Even with
Reference recorders detect readings from modules, which may these compensations, a field deadweight tester cannot actively
read pressure, temperature, current, or voltage—and store the data detect or record changes in pressure—it only offers an accurate
in their digital memory. These modules are usually interchangeable reference pressure for comparison.
and recorders generally accept two inputs at a time. In addition to A reference recorder serves two purposes. First, it stores read-
their compact size, reference recorders offer several improvements ings continually, with update rates up to 10 readings per second,
to bulky chart recorders. and allows the operator to record an
entire test from start to finish; second,
Improving On a Chart Recorder such a device will provide a consis-
Chart recorders were originally pat- tent, accurate reference for field cali-
ented in 1915. They produce a graph brations. Measurements from modern
on a moving paper chart, and rely reference recorders are independent
on ink pens mounted on mechanical of local gravity or humidity, and pro-
arms, which pivot in response to pres- duce their accuracy via a proprietary
sure. Their primary advantage is their mathematical algorithm that corrects
ability to record for extended periods for ambient temperature. Achievable
in remote locations. Chart recorders accuracies range from 0.025 percent
may be battery-powered or entirely of the indicated reading at lower
mechanical (requiring no external pressures, to 0.1 percent of reading
power), allowing them to operate in up to 15,000 PSI.
the presence of flammable materials. “A good reference recorder’s
An experienced user may provide Figure 1. Reference recorders are replacing chart recorders accuracy should not change with
for a variety of applications.
preliminary analysis on the output temperature across its operating

By Patrick Klima & David K. Porter, P.E.
reading if it sustains damage.

Reference recorders offer a reliable improvement over the
decades-old technology commonly seen in the oil & gas industry.
Replacing chart recorders, deadweight testers, and older pressure
gauges with reference recorders helps companies reduce their
equipment costs, training time, and operator error. FC
Patrick Klima is the technical writer at Crystal Engineering. After

majoring in Mechanical Engineering at California Polytechnic
State University, he wrote technical material and articles for a
variety of industries, including energy management and green
construction. His articles on pressure measurement solutions and
digital pressure gauges have been published in a variety of trade
magazines. He can be reached at [email protected].
Figure 2. Any PC can download the digital data from a reference recorder. David K Porter, P.E. is the vice president of engineering at Crystal
Engineering. He has over 25 years experience; the last 12 in the
range,” says Pronge. This is where recorders vary widely. The test and measurement field developing rugged, highly accurate,
best manufacturers will provide proof of their accuracy claims, and easy-to-use instruments. He has a degree in Mechanical
with a calibration certificate from an accredited lab, showing test Engineering from California Polytechnic State University, San Luis
data at different temperatures.” Obispo where he is still active on the Industry Advisory Board.
Do You
Replacing Multiple Pressure Ranges www.crystalengineering.net
Pressure and temperature gauges are widespread and varied
Know & Understand

in form. Gauges will continue being useful for years, because of
their portability, customizability, and affordable cost. In contrast,
Your Pumps?
their drawbacks stem from their inherent fragility and the neces-
sity to carry multiple gauges to cover a given pressure range.
According to Pronge, “Linearity and ruggedness are the two
most important features of any pressure gauge. Many pressure
Reference recorders unify the record- Larry Bachus ("The Pump Guy") is the
ing capability of a chart recorder, the co-author of Everything You Need to
Know About Pumps, one of the best
high accuracy of a deadweight tester, selling technical books on pump systems
in the world. This book is written exclu-
and the continuous measurements of sively for people who must maintain
pumps. Whereas other pump books are
a pressure gauge into one tool that is written from a design point of view, this
book is written with maintenance in
easier to use and less expensive. mind. While most technical books sit on a
reference shelf gathering dust, this book
gauges would be useful across a much larger pressure range gathers dirt smudges. Its pages get
if their sensors were more linear and predictable. Also, many creased and folded when mashed by the
lid of a photocopy machine. It gets sneezed on and splashed with snot on cold
gauges continue to display readings that appear accurate, even
mornings. It gets soaked with leaking oil, grease, and coffee. Basically, it gets
after their sensors sustained damage.” used ... because it's tremendously useful. The straightforward guidance it pro-
To overcome these challenges, reference recorders extend their vides will help you ensure the efficiency and lifespan of your pumping systems.
usability by accepting different modules, each of which covers
a wide pressure range. Within each module range, a reference To order your copy of Everything You Need to Know About Pumps,
recorder will have superior accuracy and linearity, compared to call (615) 361-7295 or order online at
most pressure gauges. The advanced self-diagnostics in refer-
ence recorders prevent the device from displaying an invalid www.bachusinc.com/books.htm.
flow update
Leading the Way

Strong R&D drives Coriolis & ultrasonic flowmeters to new heights
Shipments of Single- and Dual-Path Transit-Time
I
t is no secret that at the end of 2008 and through 2009, the
United States and much of the world experienced the most Clamp-on Ultrasonic Flowmeters Worldwide by
severe recession since the 1930s. This recession was so Region in 2011 (Percent of Dollars)
severe that even some new-technology flowmeters, such as 6.3% North America
Coriolis and magnetic, experienced a downturn. In 2010, however, 15.7% 27.2%
Western Europe
both the Coriolis and ultrasonic rebounded strongly, as did the
Eastern Europe/FSU
thermal flowmeter market. 5.1%
In 2011, the Coriolis and ultrasonic flowmeter markets world- Mideast/Asia
wide continued their torrid pace of expansion, significantly out- Japan
pacing all other flowmeter technologies. What is behind the rapid 15.2%
China
development of these two technologies? The simple answer is 22.6% Rest of Asia
that these two markets have growth factors that are not shared 2.7% 5.2% Latin America
by other flowmeter types. In addition, they have become the
Courtesy of Flow Research Inc.
focus of conferences and workshops that consume much of the
intellectual mindshare in the flowmeter world. As a result, the
major flowmeter suppliers are focusing the bulk of their research industries, as well as other applications. Battery-powered flowme-
and development efforts on these two technologies, and this is ters offer low energy consumption independent of the main power
unlikely to change in the foreseeable future. grid and can help reduce prices on the worldwide market. Battery-
powered applications are also growing for magnetic flowmeters.
Growth Factors for the Ultrasonic Flowmeter Market
✓ Greater Appreciation of the Application Advantages;
Growth factors for the ultrasonic flowmeter market include: Acceptance as the Highest Accuracy Gas Technology:
✓ Acceptance as the Highest Accuracy Gas Technology;

Ultrasonic flowmeters have become accepted as the highest accu-
✓ Technology Improvements.
racy technology for gas, and acceptance for liquids is following suit.
In fact, some users trust ultrasonic flowmeters so much that they
employ them with limited or no on-site proving. The acceleration
Greater Appreciation of the Application Advantages: in trust for gas ultrasonic meters began following approvals by the
Ultrasonic flowmeters have been gaining acceptance over the last American Gas Association (AGA, www.aga.org) for use of ultrasonic
10 years as end-users come to understand and appreciate the flowmeters in custody transfer of natural gas in 1998.
technology—although some end-users are just now discovering
the advantages and potential of ultrasonic flow measurement.
Advantages of ultrasonic flowmeters include high accuracy, high
reliability, high turndown ratios, long service life, low maintenance,
relatively low cost, valuable diagnostics, no moving parts, and redun-
dancy capabilities. Clamp-on ultrasonic flowmeters, in particular, can
offer redundancy by providing an easy check of an inline meter.
In addition to the traditional advantages, suppliers are sig-
nificantly improving accuracy, sensitivity and reliability. Energy,
including energy conservation, and other markets have the
potential to create even more demand, particularly as the tech-
nology improves to enable new applications. As oil prices have
increased, ultrasonic has played a more important role in the oil
patch and in custody-transfer applications.
Further sweetening the pot is the fact that average ultrasonic
prices are holding their own or even declining, which adds to their
appeal. In comparison, the average price for Coriolis flowmeters
has had upward pressure due to the recent introductions of large- KROHNE’s Altosonic V12 is a custody-transfer gas flowmeter that has 12
chords. Here is a transparent version of the meter on display at the 2012
line size models in the 10- to 16-inch diameter range. CEESI Ultrasonic Flowmeter Workshop to show its inner workings.
The increased use of battery power supplies opens up additional Photo courtesy of Flow Research Inc.
opportunities for ultrasonic flowmeters in the water and irrigation

By Jesse Yoder, Ph.D.
Technology Improvements: Flowmeter bent tubes, straight-tube Coriolis meters priate for straight-tube
manufacturers are focusing a great deal of have been developed that address some meters. Most straight-tube
attention on ultrasonic flowmeters, perhaps application problems with bent-tube meters use titanium, which can
at the expense of other meters such as meters. KROHNE introduced the first leach into certain products. As a result,
vortex and turbine. Suppliers have made commercially successful straight-tube stainless steel is used for some applica-
significant progress in enhancing the accu- Coriolis flowmeter in 1994. Straight-tube tions where leaching can occur. In many
racy and reliability of ultrasonic flowmeters. meters address the problem of pressure chemical applications, pressure drop is not
This has mainly been done by increasing drop because the fluid does not have to an issue, so both straight- and bent-tube
the number of paths, thereby increasing travel around a bend. This makes them meters are used. Straight-tube meters are
the number of measurement points, and better able to handle high-velocity fluids. also widely used in the food processing and
also by adding greater diagnostic capabil- Straight-tube meters can be drained more chemical industries.
ity. The enhanced diagnostic capability, it is easily, which is important for sanitary
claimed, can reduce the need for upstream applications. Liquids do not have a bend Growth in Coriolis Flowmeters for Large
piping, as well as increase the ability of or curve to build up and leave residue on. Line Sizes: The expansion in the number
the ultrasonic meter to determine sources Straight-tube meters also have a more of suppliers offering large line size Coriolis
of error. Lately, new and more accurate compact design. Bent-tube meters can flowmeters is one of the major recent
meters have been developed for custody be quite large and unwieldy, especially in headlines in the flowmeter world. Rheonik
transfer of petroleum liquids, as well as for the larger sizes. Having a more compact used to be the only Coriolis flowmeter com-
custody transfer of natural gas. meter can be an advantage where space pany to offer meters in line sizes above 6
is a concern. inches. Then Rheonik was acquired by GE
Growth Factors for the Coriolis Straight-tube meters are quite popular in Measurement, and GE Measurement contin-
Flowmeter Market the pharmaceutical industry. However, not ued to produce the large line-size meters.
Growth factors for the Coriolis flowmeter all pharmaceutical applications are appro- In the past several years, Endress+Hauser,
✓ Users Are Looking for Low

market include:
✓ Straight-Tube Meters Address Some

Maintenance;
Say goodbye to
✓ Coriolis Flowmeters for Large Lines.
Issues with Bent-Tube Meters;
Annual Fa
annual factory
ctory
Users are Looking for Low
Calibratio
n calibrations
Maintenance: Coriolis meters have a At Fox, we know your time is
reputation for being high-priced meters. valuable and annual calibrations of
However, most users today take into instruments is downtime that you
account the distinction between purchase can’t afford. CAL-V™ Calibration
cost and cost of ownership, or lifecycle Validation is an innovative solution to your needs. It can be used to streamline your
cost. Even though Coriolis meters have quality assurance, improve process initiatives, and apply scheduled maintenance
procedures. It is of particular value in environmental monitoring applications where
a higher purchase cost than many other
periodic calibration validation is mandated. Find out more about this unique technology
flowmeters, they may cost less over the by scanning the QR code below or visit our website at www.foxthermal.com/cal-v.php.
lifetime of the meter due to reduced main-
tenance costs. Unlike turbine and positive- Advanced features of the FT3 Thermal Mass Flow Meter & Temperature Transmitter
• CAL-V™ Calibration Validation

include:
displacement meters, Coriolis meters do
not have any moving parts, apart from • Optional HART or RS485 Modbus
the vibrating tube. They are not subject communication options
to wear in the way that orifice plates are. • Free FT3 View™ Software Tool
With many companies reducing their engi-
Direct mass flow measurement, exceptional low-flow
neering and maintenance staffs, having a
FOX MODEL FT3 sensitivity, fast response, and low maintenance requirements
meter that does not require a great deal of distinguish the Fox Model FT3. Insertion and Inline
maintenance can be a major advantage. types as well as local and remote configurations
are available.
Straight-Tube Meters Address Some Email us at [email protected] or call us at 831-384-4300 to find out how we can help
Problems with Bent-Tube Meters: While you bring down your energy costs and raise your process efficiency.
the original Coriolis flowmeters all had

flow update
UK’s National Flow Measurement Standards. Both


CMR and NEL are “think tanks” that work with suppliers and end-
users to solve industry problems. Some of these solutions are
presented at the annual conferences.
In addition to focusing on ultrasonic flowmeters, the North Sea
Flow Workshop focuses on multiphase flowmeters. While multi-
phase flowmeters have been around for over 25 years, the inter-
est in them has intensified in recent years due to the expanded
search for oil and gas and other forms of energy. They were the
product of a perceived need to more efficiently measure the three
primary flow elements of wellhead output—oil, gas, and water—
at a single measuring point. The idea was to effectively combine
one or more existing solution technologies into a single unit that
would provide real-time data and, if properly packaged, would
At this year’s CEESI Ultrasonic Flowmeter Workshop, industry veteran have the added benefit of portability. Many multiphase flowmeters
John Lansing talks shop with fellow attendees. During the event, it was use a nuclear source to measure density.
announced that Mr. Lansing was leaving his position with SICK to take on Coriolis flowmeters were also featured at the 2011 North Sea
a new role with CEESI. Flow Workshop. The recent development of large line-size Coriolis
Photo courtesy of Flow Research Inc.
meters by multiple suppliers has brought Coriolis meters into play
Micro Motion, and KROHNE have joined the companies offering in the energy sector. Topics addressed include their suitability
Coriolis flowmeters in the 8- to 16-inch line-size range. This devel- for fiscal liquid applications and the ability of Coriolis meters to
opment is dramatically changing the Coriolis flowmeter market. handle two-phase measurement.
One factor behind the move to larger line sizes is the need for Flowmeter conferences provide more than the ability to pres-
greater accuracy and reliability in measurement. Coriolis meters ent papers and view exhibits. A lot of interaction among the par-
are the most accurate meter made, and with no moving parts ticipants goes on at these conferences, and technical problems
have high reliability. Another major driving factor is the search for are discussed by suppliers and end-users alike. This facilitates
energy, especially in the oil & gas industry. Rising oil prices put a research and promotes the development of new features and
premium on accurate measurement of oil. And even though natural products. This type of networking is not typically going on among
gas prices have remained relatively low, the use of natural gas positive-displacement, turbine, and variable-area flowmeter suppli-
is increasing as natural gas is seen more and more as a cleaner ers and users. The growing interest in and attendance at ultrasonic,
alternative to oil. Natural gas is also viewed by many as a bridge to Coriolis, and multiphase conferences helps demonstrate that these
renewable, a bridge that may need to last at least 20 to 30 years. technologies are at the intellectual forefront of the flowmeter world.
Many of the new large line size Coriolis meters are designed for
custody-transfer applications in the oil & gas industry. Nothing Will Change & Yet Everything Will Change
It is difficult to see what can stop the ultrasonic and Coriolis flow-
Intellectual Mindshare meter markets. These flowmeters have so many advantages not
Ultrasonic flowmeters have grabbed much of the intellectual shared by other types of meters that the shift to these meters is
mindshare of the flowmeter world. Ultrasonic is one of few flow- bound to continue. The only flowmeter type that can compete in
meter technologies that have spawned international conferences terms of growth is multiphase, but multiphase meters do not
devoted to exploring new product developments and applications. compete with ultrasonic and Coriolis meters. In fact, some multi-
In 1999, Steve Caldwell of Colorado Engineering Experiment phase meters incorporate Coriolis meters as components. Vortex,
Station, Inc. (CEESI, www.ceesi.com) began an annual Ultrasonic thermal, positive-displacement, and turbine meters have their
Meter Workshop (USM). The first Workshop was held in 1999 in advantages, but they are smaller in scope compared to the
Clear Lake, Iowa, and had 30 attendees. In 2012, the 14th annual advantages of ultrasonic and Coriolis meters. So look for more
USM was held in Colorado Springs, Colo., with 213 attendees. The solid growth in the ultrasonic and Coriolis flowmeter markets, as
USM has also branched out into Santa Cruz, Bolivia, and Kuala these meters continue to displace other types. FC
Lumpur, Malaysia. CEESI is also planning to expand the Workshop
to a location in Europe in 2013. Jesse Yoder, Ph.D., is president of Flow Research Inc. in
A second conference that focuses on ultrasonic flowmeters is Wakefield, Mass., a company he founded in 1998. He has 25
the North Sea Flow Workshop. This event was held in Tønsberg, years of experience as an analyst and writer in process control.
Norway in October 2011 and attracted 330 delegates from 29 Dr. Yoder specializes in flowmeters and other field devices, includ-
countries. The 2012 North Sea Flow Workshop will be held in ing pressure and temperature products. Dr. Yoder can be reached
Scotland October 23-26. The workshop is primarily the work of at [email protected].
Christian Michelsen Research AS (CMR, www.cmr.no) and TUV
SUD NEL Ltd. NEL is involved in flow testing and maintains the www.flowresearch.com

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automation file
Under Control
Why SCADA security matters for flow control professionals
C
yber security isn’t just a media IP and COTS technologies, making them the adoption of TCP/IP as a networking
buzzword, or a priority for IT pro- vulnerable to cyber events.” technology saves money, but can expose
fessionals, it has become a real industrial networks to more cyber
concern for everyone who has an e-mail Major Trends in SCADA Security security risks.
account, banks online or uses a credit Byres has seen several major trends in
card. On a larger scale, recent events SCADA security over the last five to 10 Stuxnet & SCADA
have shown that industry too is not only years that deal with the convergence of Along with new technology shifts, the
susceptible to cyber crime, but could also company networks and industrial tech- computer worm Stuxnet set off another
be a favorite new target. Fluid handling nologies. Traditionally, companies devel- trend in the security community. Byres
professionals play an important role in oped distributed control systems (DCS) describes Stuxnet as a “game changer
keeping vital industrial systems operating and SCADA systems that were separated that awakened the hacker and ‘security
properly and safely. Whether for oil & gas, from other corporate systems. Today, researcher’ community to how easy it is
water treatment, chemical processing, or many control systems have become to cause damage to industrial systems.”
power generation, this includes ensur- accessible through non-SCADA networks Dubbed as a “super cyber weapon,”
ing plant Supervisory Control and Data due to the demand for real-time opera- Stuxnet was the first malware to specifi-
Acquisition (SCADA) Systems are secure. tional data and the demand for support cally target an industrial process. It was
When it comes to cyber security in access. The business demand to make designed to attack Siemens PCS7, S7 PLC
process control, SCADA can be mislead- control networks more accessible to a and WinCC systems and was successful in
ing. Nearly all of the process control wider range of users proves to be cost- infiltrating thousands of computers around
systems today, including PLCs, SIS, effective, but also comes with the poten- the world.
DCS, and so on, use Ethernet and TCP/ tial risk of making the control system Knowledgeable security experts had
IP for their communications. They also more vulnerable to viruses, worms and been advising and warning about SCADA
use or connect to COTS (Commercial- hackers. Some of the trends Byres sees security concerns for more than 10 years,
Off-The-Shelf) technology like USBs and are the shift from enterprise to industrial and certainly more strongly since 9/11.
the Windows operating system. Even network connections, the use of COTS However, management and the public
flowmeters today can be purchased with systems, and the adoption of TCP/IP net- largely ignored concerns until Stuxnet,
Ethernet interfaces. All of these factors working technology. says Frank Dickman, an engineering and
✓ Enterprise to Industrial Network

make systems vulnerable to some form technical consultant to leading data com-
of cyber event, whether deliberate, like munications firms. “It was a wake-up call
the Stuxnet attack that crippled centri- Connections. Businesses want real-time demonstrating that earlier warnings were
fuges at a nuclear plant in Iran in 2010, data to enhance performance and are not just hot air,” he says. “Stuxnet took the
or accidental, like the shutting down of connecting their network to the network idea of ‘hacking’ to a new definition—It is
cooling water controllers at Browns Ferry on the plant floor to get it. The result is no longer some disenfranchised teenager
Nuclear plant in 2006. increased cyber security risk. hacking away in his bedroom. Hacking is
✓ COTS—Commercial-Off-The-
In order to ensure the reliability of the current province of criminal organiza-
any system, experts say fluid handling tions, nation states, foreign competitors,
engineers need to factor in cyber secu- Shelf-Technology. Industry has been and terrorists.”
rity. “Fluid handling engineers need to adopting standard equipment such as Dickman points out there were industrial
implement good cyber security practices Windows workstations instead of pro- security products on the market that were
in order to ensure high availability and prietary equipment as in the past. While capable of detecting and blocking Stuxnet,
reliability of their systems,” says SCADA there are still many industrial-specific or other advanced persistent threats, prior
security expert Eric Byres, CTO and VP technologies being used, the adoption of to the initial discovery of Stuxnet. For
Engineering of Tofino Security (www. COTS has been compelling due to reduced example, he points to the mGuard product
tofinosecurity.com), part of Belden’s costs. Again, the result is increased cyber by Phoenix Contact (www.phoenixcontact.
Hirschmann industrial networking group. security risk. com). In its wake, Stuxnet left a blueprint
✓ TCP/IP—Transmission Control
“They can’t think that SCADA does not for cyber war and a heightened awareness
apply to them. Indeed, virtually all process of both the need for more robust cyber
control systems today use Ethernet, TCP/ Protocol/Internet Protocol. Similarly, security and the increased risks faced

By Amy W. Richardson
Industrial Control System Specific ✓ Advanced resources and expenses to eliminate it. For
Vulnerabilities in the Public, 2001–2011 Persistent Threats example, Stuxnet was aimed at a uranium
(APTs), such as the enrichment plant, but it infected thousands
complex worm known of computers around the world. Once it
as Flame, are focused was made public, it cost the “bystander”
on industrial espio- companies millions of dollars to eliminate
nage and aim to steal it from their systems.
✓ “Spear Phishing” attacks. In the

business information
rather than disrupt
processes. They are last two years both the United States and
hard to detect, they Canadian governments have announced
can hide and collect that their employees have received
data for years, and e-mails that seem to come from trusted
the losses resulting sources, asking them to download or
from them are finan- access something, leading to the installa-
Source: “Documenting the ‘Lost Decade’—An empirical analysis of cial and reputation- tion or spread of malware in government
publicly disclosed ICS vulnerabilities since 2001,” by Sean McBride, related rather than systems.
Critical Intelligence safety or environmen-
tal incidents. These Protection Through Standards
by industrial facilities. With this came the types of threats have been used to attack Some ways industry is reacting to cyber
trend of vulnerability disclosures. Ever the financial sector in the past, but now security threats in general is with new
since Stuxnet, security researchers have they are attacking industry too. technology and through new standards
✓ Malware not aimed at the plant can

been busily releasing vulnerability disclo- and certifications. Byres recommends
sures for industrial equipment, complete the ISA IEC 62443 standard, which
with exploit code, which can now be pur- still be costly due to losses in manpower originated with the International Society
chased on the Internet. According of Automation (ISA, www.isa.
to a presentation by Critical org), and has been internationally
Intelligence’s Sean McBride, The endorsed through the International
‘Lost’ Decade: An Empirical Analysis Electrotechnical Commission (IEC,
of ICS-Specific Vulnerabilities since www.iec.ch). It advises companies to
2001, 215 ICS vulnerabilities were use a “zone and conduit” model of
made public in 2011. That number dividing up their network into zones of
accounts for more public disclosure devices with similar security require-
of vulnerabilities than in the previous ments. Conduits between zones
decade. Furthermore, the publicly regulate the access to the devices in
disclosed vulnerabilities are only a the zone. This model is often a more
fraction of what exist, Byres says. realistic and cost-effective method of
providing cyber security than trying to
Key Threats to SCADA secure legacy equipment itself, Byres
Systems says. Major oil and gas and chemi-
While Stuxnet is known as the first cal companies, such as Exxon, Dow
cyber attack to target an industrial and DuPont are using this standard.
process, it will certainly not be “The ISA IEC 62443 standard pro-
the last. And threats among non- vides an excellent starting point and
industrial sectors to date, are now guidance for building IACS (Industrial
becoming threats to industry, even Automation & Control System) cyber
if in less obvious ways. Some of protection programs,” Byres says.
those concerns, according to Byres, Oil and gas refinery network segmented into zones as per the A newer certification on the mar-
include Advanced Persistent Threats ISA IEC 62443 standard. Conduits connect the zones and are ket is ISA Secure, which a number
(APTS), malware, and “spear- secured using designed-for-industry firewalls. of major vendors in flow and pro-
phishing.” Courtesy of Tofino Security cess control are moving toward,

automation file
Byres says. Honeywell was one of the “At the present time, as it has been for areas rather than spread
first, announcing in June 2011 that its several decades, IT professionals have throughout a plant. In the future,
Honeywell Safety Manager (a Safety been largely uninvolved with SCADA smart facilities will take on layered strate-
Integrated System or SIS control system) control systems,” Dickman says. “SCADA gies in which networks, control devices,
achieved ISA Secure Level 1 certification. systems remain the responsibility of and control systems are individually and
ISA Secure certification is based on a engineering and production personnel. As collectively secured.
rigorous security validation process that a result, it is imperative that engineers Going forward, Byres sees technology
starts with a Communications Robustness familiar with SCADA be involved in imple- solutions continuing to move toward more
Test (CRT) assessment phase, followed menting the security and protection of industry-focused solutions. IT firewalls
by two more assessment phases, the these systems while coordinating with and that protect against things like mail and
Functional Security Assessment (FSA) educating IT.” http breaches don’t apply in industrial set-
and the Software Development Security tings. Now there are solutions for industri-
Assessment (SDSA). According to Byres, Securing the Future al-specific protocols like OPC and Modbus.
the additional second and third assess- Looking ahead into a future where cyber These solutions also use advanced tech-
ments are where real progress in ICS and security issues will firmly remain, experts niques like Deep Packet Inspection (DPI),
a deeper investigation of communications,
and deployment of rules that takes place
Fluid handling engineers need to implement good after traditional firewall rules have been
applied.
cyber security practices in order to ensure high “In the future, SCADA systems will be
better protected through increased appli-
availability and reliability of their systems. cation of defense in depth strategies,
including use of the ISA IEC 62443 zone
and conduit model, and through the appli-
SCADA security will be found “because see “perimeter defense” models for secur- cation of technology solutions that are
they consider the underlying design, ing SCADA systems—strong on the out- designed from the ground up for industrial
development practices and vendor-recom- side, but vulnerable on the inside—falling requirements,” Byres says. FC
mended deployment of the product, rather to the wayside in favor of multiple-point
than just whether it stands up to some security. Today, sophisticated companies Amy W. Richardson is the managing edi-
bad traffic,” Byres wrote in a Tofino blog are already choosing “defense-in-depth” tor of Flow Control magazine. Contact her
post in 2011. strategies that include zones that allow at [email protected].
security problems to be contained in small
New Security Solutions for
Industry
SCADA security products are also under-
going a transformation. Until recently,
5 Key SCADA Security Resources & Trainings
security products have been designed
largely for the needs of IT personnel and Tofino Security Blog: Eric Byres and other cyber security experts blog
1 regularly about SCADA security at www.tofinosecurity.com/blog.
enterprise applications, not for control
engineers and industrial control systems.
But now a number of new products, such United States Computer Emergency Readiness Team (US-CERT):
2 Follow ICS CERT announcements and subscribe to receive them at
as the Honeywell Modbus TCP Firewall and
the Tofino Industrial Security Solution, have www.us-cert.gov/alerts-and-tips.
been specifically designed to secure highly
critical control systems. Unlike IT-focused National SCADA Test Bed (NSTB) Advanced Training: Red Team/Blue Team
security products, new products have
3 training exercises are held at the Idaho National Laboratory.
been developed with the environment and (www.inl.gov/scada/training/advanced_scada.shtml).
requirements of the process control world
in mind. They are specially engineered SCADAhacker: Security expert Joel Langill offers cyber security training,
to handle harsh operating environments 4 ICS (DS/SCADA) security services, and security research and development
and support industrial communications at www.scadahacker.com.
protocols. Further, new industrial security
products can be installed, configured, and Exida: This company offers cyber security certification, training, software,
updated without having to shut down the 5 resources, and more at www.exida.com.
control network.

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the pump guy By Larry Bachus
mailbag: ‘The Energy Audit’

The importance of having your priorities straight
Pump Guy, and you hope people will take your rec-
ommendations to heart, let me say that
I am the principal engineer at an energy replaceable wear rings are a desirable
company in upstate New York. We perform option to consider when purchasing a new
energy audits. We have an upcoming audit pump.
on some pumps. I have some questions Cheap pumps (the pumps that normally
because I have never worked in mainte- win a competitive bid) don’t normally carry
nance. replaceable wear rings. As the clearance
What are pump wear rings? I heard erodes on a cheap pump, it is necessary
that you can improve the performance to install a new impeller and casing to
of a pump by coating the internals with repair the pump. Thus, the cheap pump
epoxy. Have you mentioned this in your lubricity) of the liquid, and any entrained becomes more expensive to own and
articles? Is there something I can read on solids (crystals, sediment, contaminants) in maintain than a well-built pump.
this topic? the liquid. The rings actually separate zones I have written about epoxy coatings in
of high pressure in the pump (discharge previous articles. Epoxy coatings are good
Ronald A., PE pressure) from zones of low pressure in the where rogue solids (sediment, crystals, fine-
pump (suction pressure). slurry) can accelerate damage and erosion
Hello Ronald, This clearance and the recirculation of to the pump internals. The epoxy provides
liquid through the gap
I’m glad to know someone in the energy becomes part of the
sector is thinking about pumps and the pump’s total efficiency.
energy to operate a pump. I’ll offer some The total efficiency
thoughts on wear rings, coatings, and con- is composed of the
serving energy. mechanical efficiency,
Wear rings are also called wear bands. the volumetric efficiency
Neither of these terms describes the func- and the hydraulic effi-
tion and purpose of these rings. The rings ciency.
are not designed to wear, although it hap- Over time, there
pens. A better word is “Efficiency Rings” or is wear or erosion at
“Efficiency Bands.” the strict clearance.
Wear rings are concentric metallic (or A small portion of the
other material) rings used on some pumps pumped liquid recircu-
with enclosed impellers to control and lates through the wear
maintain the pump’s original efficiency. rings as high pressure
The inner wear ring normally seats onto searches for low pressure (Pascal’s Law). a harder surface to the pump internals. The
the outside diameter of the eye of an The erosion is accelerated if the liquid coating should be reapplied periodically
enclosed impeller. This ring locks into carries crystals or sediment. The gap is because the coating also erodes.
place and rotates with the impeller. Dual- destroyed if there is misalignment or shaft I think it is a stretch to say the epoxy
suction impellers have two wear rings. The deflection leading to rubbing and scraping coatings will improve the efficiency and per-
outer ring is normally static and seats into between the rings. formance (head and flow) of a water pump.
a bore in the pump casing. As the gap erodes between the inner and Instead, I’ll say the epoxy coatings can
There is a gap or clearance between the outer wear rings, more liquid is recirculated recover some of the pump’s lost efficiency
outside diameter of the inner ring and the inside the pump, and the pump loses volu- and lost performance from erosion. The
bore (ID) of the outer ring. The clearance metric efficiency, and thus total efficiency. epoxy coatings can extend the service life of
is typically 0.006” to maybe 0.030”. The The wear rings can be replaced to return a water pump with periodical re-coatings.
clearance is a function of pump size, design, the pump to original factory efficiency. You ask about wear rings and epoxy
purpose, and the nature (temperature, Ronald, because you do energy audits coatings because of your energy audit. We

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PRESSURE & TEMPERATURE INSTRUMENTS STRATFORD, CT 06614-5145, USA
TEL: 203-378-8281 • FAX: 203-385-0408
email: [email protected]

the pump guy
should all be concerned with energy and where the pump may be only 35 percent who are operating their pumps for days
energy savings. efficient. Compare 35 percent efficiency and weeks against a closed valve, or a
An eroded gap in the wear rings can to 80 percent efficiency. Over half of the totally clogged downstream filter. Some
cause the pump to lose maybe 2 percent pump’s efficiency is out the window. How operators leave pumps running long after
efficiency. Replacing the wear rings can does this compare to the 2 percent effi- the suction tank is drained and empty.
recover those lost efficiency points. Epoxy ciency loss with eroded wear rings? These pumps are 0 percent efficient for
coatings can recover some of the pump’s Low system resistance (for example, hours, days, weeks, and months.
lost efficiency from erosion and scale. inadequate pressure in a downstream Of course the mysterious vibrations go
This is peanuts and not worth 30 header, with no transducer to report it in up. This is the reason reliability engineers
minutes of banter in a Friday morning the control room) might drag the pump to invest in vibration analysis for their pumps.
Reliability Meeting. Pipe system design the right end of the performance curve, (Now I’m rubbing your nose in it. But you
and pump operation influence efficiency where the efficiency might be only 40 knew that. Didn’t you?)
and performance much more than epoxy percent. How do you feel now about your Pumps consume maybe 20 percent
coatings, or an eroded gap on a set of efficiency gains with epoxy coating? of the world’s available energy. Keeping
wear rings. I’ll offer a verbal illustration. Maybe a process engineer needs more these pumps at optimum efficiency is
Let’s say you need a pump to deliver temperature in a pressurized downstream critical. If I were performing an energy
a liquid at 600 GPM. Your pipe arrange- reactor vessel fed by a process pump. audit, and making recommendations to
ment, elbows, valves, fittings and process
devices will eat 90 ft of energy. Flow can
oscillate plus or minus 10 percent. You
need a pump that develops 600 GPM at
“If I were performing an energy audit, and making
90 ft of head. The best pump for this ser-
vice might be 80 percent efficient at these
recommendations to save energy (money), I’d look
duty coordinates.
The pumping system is designed to allow
first at pump operation and system design.”
(restrict) this pump to operate at or close
to 600 GPM @ 90 ft. Let’s say the system The back-pressure on the pump will rise save energy (money), I’d look first at pump
is designed to allow the flow to oscillate with the increased temperature. The pump operation and system design.
between 540 GPM (minimum) and 660 deadheads against the system and flow Show your customer how he or she can
GPM (maximum). The head will oscillate stalls at 0 GPM and 0 percent efficiency. save 30–60 points of efficiency on each
between 87 ft (min.) and 93 ft. (max.). (The motor is on, but no work or produc- pump in the plant. Don’t waste his or her
If the system is designed with this tion is performed at 0 GPM. Efficiency is 0 time talking about 2 percent efficiency
operation window, the pump would always percent.) savings. Wear rings and epoxy coatings
be between 78 percent and 80 percent There is no flowmeter to report the are way down on the priority list.
efficient, or within two points of best effi- problem because flowmeters are expen- Some industries like oil refineries, phar-
ciency. This is everything you might have sive. So, the operator assumes he is maceutical plants, food production (soup,
gained or lost with those replaceable wear pumping into the reactor vessel because dairies, beer, vegetable oil) and municipal
bands or the labor-intensive epoxy coat- the motor is on and the valves are open. water distribution are pump intensive.
ings, and you don’t have to rebuild the Before long, this pump will go to the Eighty percent of the monthly electric bill
pump to accomplish it. That’s why I use shop with premature seal or bearing fail- goes through the motors and pumps to
the word “peanuts.” ure. And while in the shop, the engineer move, mix, filter, heat, ferment, refine,
If the pump operators aren’t trained to tells the mechanic to replace the eroded strain, cool, and bottle liquid products.
monitor instrumentation, or if the opera- wear bands to recover 2 percent efficien- The “bean counters” need to look seri-
tors have no gauges to consult, or if the cy. Am I making sense? ously at system design and operator train-
operators don’t know how to correct the I know there are pump operators who ing. The engineers and operators, with
pump as the system changes, the system don’t pay attention to their instrumentation some training and a few gauges, can turn
can drag this pump away from these duty (gauges, flowmeters, level indicators). And all pumps into energy stars of efficiency.
coordinates. Here are three classic exam- there are many more pump operators with A good pump operator can compensate
ples to illustrate how this might happen in no gauges to interpret. They do the best for inadequate system design and system
a process plant. they can with the cards they were dealt by upsets.
Elevated system resistance (a clogged the production engineer. Remember, the driver (the operator) has
downstream strainer, for instance with no As I write these words, there are a few the most influence on a car’s efficiency.
instrumentation to report it) could drag pump operators in every process plant, The driver (operator) determines if a car
and hold this pump to 200 GPM for hours refinery, and power plant all over the world is a high-maintenance car or a low-main-

This Is NOT Your
AVERAGE TRAINING
Are your engineering, maintenance
and operations teams struggling
with persistent pump problems?
“I thought this seminar was one of the best I’ve
attended in my career. Larry gave me the practical
tools/steps to analyze a pump system. Now I feel I can
go back to my plant and look at a few systems that we
seem to be working on too much.” THE PUMP GUY
– Attendee comment, Houston 2010
CAN HELP!
“Excellent presentation! While I have done system
calculations (i.e., “pump calculations”) for over 15 years,
I can see that what I have been doing has missed the
mark in a lot of cases. Thanks to Larry, I now know how
to provide a good calculation/analysis of a system that
will truly meet its extremes of operating.”
– Attendee comment, McIntosh, Ala. 2011
“For my line of
work, this seminar was
dead on. It met my needs fully.
Best money my company has ever
spent for a training course.”
– Attendee comment,
New Orleans 2009
For more information & to register for the

Oct 16-18 Pump Guy Seminar in Los Angeles,
visit FlowControlNetwork.com/PumpGuy.
the pump guy
tenance car. The driver determines the Incorrect clearance on a pump’s wear than you wanted. I perceived you were
ultimate service life of a car. bands can cost a pump maybe 2 or 3 looking for some guidance to help with
If I were performing an energy audit at efficiency points. This is not trivial but it is your recommendations after you conduct
a power plant, refinery, hospital, chemical inconsequential compared to the energy your energy audit on your client’s pumps.
plant, or municipal water plant, I’d recom- savings of proper system design and Good luck with the audit. FC
mend that we look critically at pipe and operator training.
process system design and pump operator Our industry dedicates much effort, Larry Bachus, The Pump Guy
training. With little effort and time, the pipe many words, and even more dollars into
systems can be improved or modified so proper alignment and balance. Laser align-
The Pump Guy Seminar will be in
that all pumps run at their optimum effi- ment and dynamic balance can recover
Los Angeles, Oct. 16-18. See the
ciency with minimal operator intervention. (not improve) maybe 2 percent lost effi-
previous page for details and visit
Cheap pumps are generally inefficient ciency from misalignment and imbalance.
FlowControlNetwork.com/PumpGuy.
pumps. A high-efficiency pump can be But it can’t compare to proper system
5–10 efficiency points better than a com- design and correct equipment operation.
parable cheap pump. A purchasing agent I believe in lubrication. A lubrication pro- Larry Bachus, founder of pump services
may think he saved his company $1,000 gram is vital. Inadequate lubrication is easy firm Bachus Company Inc., is a regular
on a pump purchase and not realize that to improve. However, a pump operating on contributor to Flow Control magazine. He
the electricity for the cheap pump will cost the extreme of its performance curve is 0 is a pump consultant, lecturer, and inven-
$4,000 more per year due to poor efficien- percent efficient even with the best, high- tor based in Nashville, Tenn. Mr. Bachus
cy. The $1,000 savings on the invoice is a est quality, synthetic grease or oil on the is a retired member of ASME and lectures
one-time savings. The $4,000 additional bearings. So why do we pay attention to in both English and Spanish. He can be
energy will hit the company every year lubrication and do nothing about inadequate reached at [email protected].
the pump is in service. And the cost per system design or operation?
kilowatt-hour will rise over time. Ronald, this may be more information www.bachusinc.com
The 2012 American School of Gas Measurement

Technology will be held September 17-20 at the
Marriott Houston Westchase Hotel, Houston Texas
The ASGMT combines Lecture and Hands-on

Classes, Plant Tours, Educational Exhibits Educating the
and networking functions with the objective Measurement
of providing the skill sets required to safely Professional
and effectively install, operate and Since 1966
maintain natural gas transmission and
distribution measurement facilities.
Registration fee $125. Registration increases

to $150 after August 30, so register early.
Continuing Education Units (CEUs) through
Texas A&M Kingsville are also
available for an extra $33.
American School of Gas Measurement Technology
To register online or for additional
information, visit our website at September 17-20, 2012
www.asgmt.com Marriott Houston Westchase
Training the Natural Gas Industry to Meet Tomorrow’s Needs.


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/freeinfo.
Pipeline Mixer for High-Shear Mixing

Chemineer Inc.’s Greerco Pipeline Mixer is designed for continuous high-
speed, high-shear processing for applications involving homogenization, mixing,
dispersion, and emulsion. This mixer features a patented skewed turbine/stator
unit, which operates at tight tolerances to produce high-shear axial mixing.
With pumping capacities from 10 to 1,300 GPM, the pipeline mixer is used in
the cosmetic, chemical, pharmaceutical, petrochemical, and food industries for
a range of applications including lotions, creams, dispersions, resins, solvents,
and sauces. Standard models feature 316 stainless steel construction and
single mechanical seals with other options available. Sanitary models are also
available.
FREE INFO: WRITE IN 104 | www.chemineer.com
Detachable Electric Ball Valves Pressure Reducing Regulator

From the W.E. Anderson Division of Dwyer Instruments Emerson Process Management’s
Inc., the Series HBAV & 3HBAV electrical ball valves high-capacity, pressure reducing
are a good fit for flow control in hot Tartarini 10-inch Type FL regulator is
and cold water HVAC systems. a pilot-operated regulator that is
These valves are typically a good fit for high-pressure drop
used in conjunction with applications, such as city gate
air conditioning systems, stations, power plant fuel supply
heating systems, water and turbine fuel supply. The SR
treatment, and produc- II noise attenuation option can
tion industries. The HBAV reduce noise levels as much as
& 3HBAV are electrically 20 dB(A) depending on flows and
driven to open and/or close via pressure drop. The FL can also be con-
a bidirectional AC motor. Featured figured to be used as a relief valve or back-
with the electrical valve is a detach- pressure regulator.The regulator complements Emerson’s cur-
able actuator that has a manual switch rent family of 1-, 2-, 3-, 4-, 6-, and 8-inch-size FL regulators. It
and position indicator. Both are available in a handles higher capacities while providing all of the benefits of
modulating or floating version. the other FL sizes, such as true no-bleed design, easy startup,
FREE INFO: WRITE IN 105 | www.dwyer-inst.com noise attenuation options, balanced trim design, bubble-tight
shut off, 1,480 PSIG inlet/outlet rating, control accuracy, and
modular design.
FREE INFO: WRITE IN 106 | www.emersonprocess.com
3-Inch Diaphragm Pump

Graco’s Husky 3300, a 3-inch (76.2-mm) air-operated double-diaphragm pump family fea-
tures a modular, stall-resistant air valve design, which can achieve flowrates up to 300 GPM
(1,135 lpm). The pumps also utilize a pilot valve for faster changeover, maximizing efficiency
and reducing pulsation. The pumps are available in three materials of construction, including
aluminum, polypropylene and stainless steel. In addition, there are ball, seat and diaphragm
material configurations to handle a range of abrasive and corrosive applications. The pumps
also have a four-bolt joint design, which provides even sealing pressure for leak-free opera-
tion and a three-piece manifold for increased installation flexibility. The new polypropylene
version has a fluid section containing an overmolded frame that decreases joint relaxation
and increases strength to eliminate fluid leakage.
FREE INFO: WRITE IN 107 | www.graco.com/husky

Plunger Valve for Water Systems Digital Humidity/Temperature Sensors
Henry Pratt Innovative

Co.’s Series 300 Sensor
Plunger Valve Technology’s
is designed to Hygrochip Series
reduce cavita- digital humidity
tion and stagnant sensors combine
water creation the advantages of
to help water a precise capaci-
systems improve tive humidity sensor element with the high integration density
operational safety, and functionality of an ASIC. The integrated signal processor
efficiency and flow receives the measured data and directly delivers the physi-
control. The plunger valve features a field-replaceable control cal parameters of relative humidity and temperature over an
insert that enables water systems to effectively reduce flow I2C compatible interface. Both nonlinearity and temperature
pressure while reducing cavitation levels. It contains a valve dependence are corrected “OnChip” by computation, to ensure
actuator mechanism that provides non-linear closure with accuracy (+/- 1.8 percent rH, +/- 0.2 C) for a range of appli-
precise surge resistance and effective control ranges as high cations. Compared with monolithic solutions, the new digital
as 96 percent. The plunger’s o-ring seal, which is located humidity modules offer notable performance advantages. The
outside of the cavitation zone, and four hard-faced cylinder P14 humidity sensor, featuring a high performance polymer, is
support guides work together to help minimize wear and pro- characterized by high chemical resistance, ability to recover
vide the valve with a longer operational lifespan. The valve’s after dew formation, and long-term stability in critical applica-
input shaft features a dual inboard seal that helps protect the tion areas with high humidity.
shaft and the shaft bore from corrosion while helping to avoid FREE INFO: WRITE IN 109 | www.ist-usadivision.com
stagnant water creation.
FREE INFO: WRITE IN 108 | www.henrypratt.com
Wet/Wet Differential Pressure Transmitter

Omega’s PX5200
series of range-
able wet/wet dif-
ferential-pressure
transmitters are
CE-compliant,
compact trans-
mitters that
feature a backlit
display for easy
Level Problems?
reading. The
series also features stainless steel, FKM, and ceramic WE CAN HELP
wetted parts. It comes with a flow measurement total- >> Troubleshoot Problem Level Instruments
ization/square root extraction function, program lock >> Assess Billing Level Instrument Accuracy
function, and is quick ranging with internal pushbuttons,
and a backlit display that rotates in 90-degree incre-
>> Close Material Balances
ments to fit the location. The transmitter has rugged, >> Improve Level Instrument Accuracy
aluminum NEMA 4X (IP65) enclosure measures, which >> Select and Specify Level Instruments
make it a good fit for flow and tank level applications >> Train Your People
where low differential pressure measurements are
required.
WE KNOW LEVEL!
FREE INFO: WRITE IN 110 | www.omega.com www.spitzerandboyes.com • 1.845.623.1830

new products
All-Electric Actuators No-Valve Metering Pump

Rotork’s CMA series of all-electric Watson-Marlow
modulating actuators are sized Pumps Group’s Qdos
for linear, quarter-turn and rotary 30 is designed to
control valve and pump applica- eliminate ancillary
tions requiring precise position equipment, enhance
control and continuous modulation. productivity, and
They can be powered by single- reduce chemical
phase or direct-current supplies, waste through more
eliminating the need for air hoses accurate, linear, and
and compressors used with similar repeatable metering
pneumatic control valve actua- than typical solenoid
tors. Set-up and configuration is or stepper-driven
done via pushbuttons and an diaphragm metering
internal six-segment LCD display. pumps. The Qdos 30
Resolution is 0.25 percent on lin- pump range deliv-
ear and quarter-turn applications ers a 5,000-to-1 flow from 0.002 to 8.0 GPH at 100 PSI
and 2 degrees on the multi-turn while integrating easily through IP66 manual, analog, and
configuration. Other features PROFIBUS control options. Featuring Watson-Marlow’s pat-
include a permanently lubricated ented ReNu pumphead technology, the pump is fully sealed
and maintenance-free drivetrain; a for safe, tool-free maintenance. There are no seals or valves
4-20 mA loop-powered, feedback signal; and digital commu- in the flow path to clog, leak or corrode. Advanced control
nication options including HART, Foundation Fieldbus, Profibus, features include fluid level monitoring, fluid recovery, line
Pakscan, RIRO, and Modbus. priming, and intuitive flow calibration. Applications for this
FREE INFO: WRITE IN 111 | www.rotork.com pump range include disinfection and pH adjustment of drink-
ing water and industrial process water; flocculation; industrial
cooling water preparation; reagent dosing in mineral process-
ing, and more.
FREE INFO: WRITE IN 112 | www.wmpg.com
Large Size Magnetic Flowmeter

Yokogawa has expanded its lineup of ADMAG series mag-
netic flowmeters to include the AXW large size magnetic
flowmeter. The AXW series is a good fit for industrial pro-
cess lines, water
and other basic
applications. Sizes
are available from
500 mm (20 in.) to
1000 mm (40 in.)
with a wide liner
selection such as
PTFE, hard rubber
and polyurethane
lining. The AXW
series comes stan-
dard with ASME,
AWWA, EN, JIS,
or AS flanges. A
submersible version is also available. The design is robust,
featuring a shorter face-to-face dimension for a smaller
footprint and an easier, cost-effective installation.
FREE INFO: WRITE IN 113 | www.yokogawa.com/us

Fluid Handling Reference Shelf
Literature
Automation Product Catalog

Omega Engineering’s FREE LITERATURE New Horizons in Automation Version No. 30 con-
tains over 100 full-color pages of the latest state-of-the art products from Omega’s auto-
mation line: programmable logic controllers, smart relays, enclosures, process measure-
ment and control devices, motion control sensors, human machine interface, pushbuttons,
proximity sensors, relays and timers, wire connection, and more. A user-friendly index is
available for easy product search, economical choices, popular models and accessories.
As you flip through Omega’s impressive line of products, enjoy pages of original Rube
Goldberg cartoons! To request your copy of this handbook, visit omega.com.
FREE INFO: WRITE IN 200
PVC Hose & Tubing Industrial Flow Measurement

Kuriyama’s new Kuri & Control Solutions
Tec® PVC Hose & Badger Meter Inc.’s (BMI)
Tubing catalog fea- industrial product brochure
tures the company’s features the company’s
new Klearon™ 68 product offerings in agricul-
Series tubing with a tural, automotive, commer-
68 Shore “A” rating; cial, and industrial process
Series 3300, an ether- applications. Advanced flow
based polyurethane- measurement and control
lined clear PVC tub- solutions, data manage-
ing; and the Series ment software, and techni-
A1730, a flexible FDA cal support services are
polyethylene hose for highlighted in the literature.
handling a variety of fluid-transfer applications. Contact To download a PDF of the Badger Meter brochure, visit
Kuriyama at 847 755-0360, kuriyama.com, or sales@ badgermeter.com/industrialbrochure.aspx.
kuriyama.com. FREE INFO: WRITE IN 201 FREE INFO: WRITE IN 202
DotComs
www.cmeflow.com www.smartflow-usa.com butechvalvecatalog.haskel.com
Measure Gas Flow Accurately Cooling Water Accessories High-Pressure Valves & Fittings
CME offers a complete line of lami- Smartflow-usa.com features cooling Haskel International’s interactive e-cat-
nar flow elements, analog and digital water-handling accessories, including alog contains a comprehensive product
flowmeters and flowmeter calibra- water mani- catalog and configurator. It features all
tors for both laboratory and process folds, and standard BuTech high-pressure valve and
applications. Visit us online to view our mechanical component
accurate, dependable, NIST-traceable and elec- products.
flowmeters. FREE INFO: WRITE IN 203 tronic flow- It’s intuitive
meters. See navigation
all new features of the Tracer Switching menu walks
Flowmeter, now with analog outputs users through
for flow and temperature. The Tracer a selection
includes Fluid Condition Indicator “FCI” process using
for Turbulent Flow indication based on formula-assisted parameter selection,
water temperature and line size. full/partial product number, or descrip-
FREE INFO: WRITE IN 204 tion/keyword. FREE INFO: WRITE IN 205

Advertiser Index
Find company websites and get free product information online at www.flowcontrolnetwork.com/freeinfo.
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
Name Page RS # Name Page RS # Name Page RS #
American School of Dynamic Flow Computers 35 17 Kuriyama of America 45 201

Gas Measurement 40 19
Endress+Hauser IBC, BC 23, 24 The Lee Company 5 4
Ashcroft Inc 37 18
Magnetrol International 13 25
Fox Thermal Instruments Inc 29 16
Assured Automation 21 14
Nanmac Corporation 10 7
Flow Control Career Center 31 NA
Bachus Company Inc 27 NA
Omega Engineering Inc 1, 45 2, 200
Flow Research Inc 17 12
Badger Meter 45 202 Process Flow Direct 41 20
GPIMeters.com 3 3
Burger & Brown Porter Instrument – Parker 9 6
Engineering – Smartflow 45 204 GF Piping Systems IFC 1
Pump Guy Seminar 39 NA
CheckAll Valve Mfg Co 11 8 Haskel International 45 206
Sage Metering Inc 7 5
CME Aerospace Innovative Sensor
Control Products 45, 48 203, 22 Spitzer & Boyes LLC 12, 43 9, 21
Technology 19 13
WEFTEC 25 15
Collins Instrument Co 15 10 John C Ernst Company 16 11
PRODUCT INDEX Page RS #

FREE
PRODUCT INFORMATION ONLINE American Sensor

Follow these 4 steps to receive free product information from suppliers.
Technologies 24 100
1 Go to: www.flowcontrolnetwork.com/freeinfo
2 Select appropriate issue of Flow Control Magazine. Chemineer Inc 42 104

3 Select advertisements that interest you.
4 Enter your email & click “Submit Request”. Emerson Process

Management 42 106
Dwyer Instruments 24, 42 103, 105
Graco 42 107
Your Source For Fluid Handling Videos Henry Pratt Co 43 108

YouTube’s for fun; FlowTube ’s for fluid handling knowhow.
Place your fluid handling videos on FlowTube, the only fluid Innovative Sensor
handling-specific Internet video repository for end-users. Technology 43 109
FlowTube sponsors receive: NEWPORT Electronics 24 101

•฀ ฀Premium฀placement฀on฀FlowControlNetwork.com
•฀฀A฀branded฀FlowTube video page with company
logo, live links, video archive, etc. Omega Engineering Inc 24, 42 102, 110
•฀ ฀Featured฀placement฀in฀monthly฀FlowTube e-blast
to 45,000 fluid handling professionals
•฀ ฀Featured฀placement฀in฀the฀Flow Control
Rotork Process Controls 44 111
e-news to 45,000 fluid handling professionals
Watson-Marlow Pump Group 44 112
For more information about FlowTube
sponsor packs, e-mail [email protected]. Yokogawa 44 113

think tank
June Winner: William Knopke, Production Manager, GLOSSARY OF TERMS: MicroElectroMechanical Systems (MEMS)
ISurTec (St. Paul, Minn.)
ACCELEROMETERS: An example of a MEMs device, accelerometers are used for
Solve This Word Search measuring rate of velocity in direction or speed and often feature high-resolution,
Win a $50 Best Buy Gift Card smart-embedded functionalities and advanced power-saving features.
One lucky entrant who has solved the puzzle correctly will win a
$50 Best Buy gift card. Best Buy is North America’s leading con- ANISOTROPIC ETCHING: Wet etching process used to create a functional MEMS
sumer electronics retailer. You can use your gift card in the store or structure. This directional chemical etching depends upon the crystallographic
online at www.BestBuy.com.
orientations of silicon such as <111>, <110> and <100>.
Fax solution to: (205) 408-3799
If there are no completely correct entries, a winner will be ANODIC BONDING: Used in MEMS processes, anodic bonding is the process of
selected from among the entries with the most words found.
bonding a conductor to an insulator in presence of high voltage and temperature,
I would like to receive/continue Flow Control magazine: _____ Yes _____ No.
such as silicon to glass.
Signature: _______________________________ Date: _______________
Name: _____________________________________________ BORON: P-type dopant is used to make strain gauges in silicon-based
Title: ______________________________________________ pressure sensors.
Company: __________________________________________
Address/City/State/Zip:_________________________________ CVD: CVD, or Chemical Vapor Deposition, is the process technique for depositing
__________________________________________________ metal and insulating thin films involving reaction of gaseous mixtures.
Phone: ____________________________________________
E-Mail: ____________________________________________ DOPING: A process where boron or phosphorus is used to alter the conductivity
of silicon.
R A N G N P R E S S U R E B O R O R R G S
E I G N I H C T E C I P O R T O S I N S C DRY ETCH: Etching and sculpturing of silicon using Deep Reactive Ion Etching
M M N A N O D I C B O N D I N G E I E G U (DRIE) without chemicals.
H D C I D O D A P I N G L T N T H R R N R
I S T R V L A C S E P E A I E C U D C I N
ETCH STOP: Allows for predetermined thickness of silicon specially related to
S R E U C D P D O C G E N R T T E E D H A
O E Y S G C R E I N I I U E C S R I R C E
diaphragm thicknesses of a MEMS device.
T T R S G S E N U L H T C U H U Y R Y E G
R E D E N S S R I C C I R C S C C B E C I ISOTROPIC ETCHING: This wet etching process features chemical etching or milling
O M I R I H S S A U P T T E T A T C O I A
of silicon structures at the same rate in each direction.
P O O P P E U M R O S E R Y O R T T I P N
I R T L O R O S R O H P O T P I S D P O C
C E T O D R O T R R S C U P A S C A L R T MASK: Photographic image of a layer for special processes such as oxidation,
E L S S C R O C R T E C H S T O P N M T N metallization, etching, and diffusion in silicon.
T E O I C S I A I O O H C T E Y R D T O O
C C M I I M A C C E L E R A M E T E R S I
MICROMACHINING: Fundamental technology for fabrication of MEMS devices,
I C M N C O R R B M B O R O O N E I H I D
N A A D M B G P H O E N O C C I L I S N R
micromachining involves the process that fabricates three-dimensional
G M D I R A I T I N R S N O C I L I S A C
microstructures.
D O P I N O S O U E I O K I E G N A R C R
R G R R S P C K O A T D N C M G I O N S A MICROSTRUCTURE: Featuring small structures that range from millimeter to
micrometer range. This is the essence of MicroElectroMechanical Systems.
ACCELEROMETERS ISOTROPIC ETCHING
PASCAL: An international unit of pressure (Pa) widely used throughout the world.
ANISOTROPIC ETCHING MASK Pa is rapidly replacing the use of pounds per square inch (PSI) unit.
ANODIC BONDING MICROMACHINING PRESSURE: The force acting over a surface expressed in terms of force-to-area ratio.
BORON MICROSTRUCTURE RANGE: Measurement values specified by the upper and lower limits of a sensor.
CVD PASCAL
SILICON: Silicon sensors made from silicon employing both electrical and mechani-
cal properties of silicon.
DOPING PRESSURE
The terms and definitions for this word search were provided by Karmjit Sidhu, Vice
DRY ETCH RANGE President Business Development, American Sensor Technologies (AST, astsensors.
com), a manufacturer of MEMs pressure sensors, pressure transducers, and pressure
ETCH STOP SILICON transmitters.

think tank
By David W. Spitzer
quiz corner: Charles’ Law
where V is volume and T is the absolute temperature. In this
I
ncreasing the temperature of a gas from 30 C to 60 C will
increase its volume by approximately: application, T0 is approximately 300 Kelvins (273+30) and T is
approximately 330 Kelvins (273+60). The new volume is therefore
approximately 1.1 times (330/300) times the old volume, so the
A. 0 percent (no volume change) new volume is about 10 percent greater than the old volume.
Therefore, the correct answer is Answer C.
B. 5 percent
Additional Complicating Factors
C. 10 percent Charles’ Law was used above assuming that the gas is ideal. If
the gas is not ideal, other methods can be employed to account
D. 50 percent for non-linearity and pressure effects on density such as the Non-
Ideal Gas Law, density tables, or other such techniques. In actual
E. 100 percent applications, remember that the composition of the gas can
change and affect these calculations. FC
Commentary David W. Spitzer is a regular contributor to Flow Control maga-

For flow measurement purposes, Charles’ Law is often used to zine and a principal in Spitzer and Boyes, LLC offering engi-
calculate the change in volume that occurs when temperature neering, seminars, strategic, marketing consulting, distribution
changes: consulting and expert witness services for manufacturing and
automation companies. He has more than 35 years of experience
V / V0 = T / T0 and has written over 10 books and 250 articles about flow mea-
surement, instrumentation and process control.
GAS FLOW ACCURACY

ASSURED
Mr. Spitzer can be reached at 845 623-1830 or
www.spitzerandboyes.com. Click on the “Products” tab in the
with Model 60B Flow Computer
navigation menu to find his “Consumer Guides” to various flow
and level measurement technologies.
JULY SOLUTION: Pressure Measurement

Model 60B Flow
Computer P I R T R A N S D U C E R C L V E S S S
The 60B Flow Computers con- P E E S T R A I N G A U G E S E E R R A
stantly process pressure, temperature and
R S G E G U A G E R U S S E R P G O E N
flow data from a Laminar Flow Element (LFE)
with a resulting accurate (± .75% of point- E O U U P S B E Y L O S L A W E L T G U
NIST traceable) display of Standard (Mass) S E L R A R R E T T E M O N A M O A U U
and Volumetric flow. Totalizers and optional
outputs are available. S C A U S G E T R V E B O Y L E S L A W
FCS-9003 Portable Calibrator
U T A E A M N S R E G U L A T E R U G E
Save downtime and money with the FCS 9003 portable Flow Calibrator. It utilizes
R E H R S P L A S M A S H I E L D G E E
a custom Windows™ based program to provide superior calibration of many dif-
ferent flowmeter types. The portability of the system saves test time and the soft- E E S R P O L E I U U R V G P E R E V L
ware compensates for flowmeter types and test conditions eliminating manual C O E U O E N A S T R E N P L R O R I L
calculations. Print and store compliance data reports after each calibration.
O E L R O T E T L M S E S R A D S I T E
For more information on the Model 60B Digital Flow Computers, the FCS N T R E M O T E S E N S O R S I N R I P
9003 Portable Calibrator or any of these CME products:
T E M C D R M L L I S S E V M A I U C P
Laminar Flow Elements • Mass/Volumetric Digital Flowmeters • Custom Test
Stands • Analog Flowmeters • Digital Manometers & Altimeters R M U U C V U P E M E T M A A P S S A A
See us at: www.cmeflow.com

Call Rich Kennedy, 800-845-0927 O O L D S T U L C V E N D C S H E S P A
L N E S S S C S S M A T S U H R T E A A
L A N A R I A P O V S L O U E A O R C E
The originators of gas laminar flowmeters
/Div. of Aerospace Control Products, Inc. E M C R L D V N L P G U V A I G M P P S
1314 West 76th Street, Davenport, IA 52806 • FAX: 563-391-9231 R S V T D I A P H A G M V E L M E S L N
E-mail address: [email protected] H H O V E M E O H U L I E R D R R E O L

Your instruments tuned to perfection.
Just as a piano needs to be tuned to ensure a perfect pitch, so do c ritical process measurement instruments. Calibration servi ces
from Endress+Hauser deliver the skills and tools necessary to ensure your quality, safety, or environmental measurement devi ces
are tuned to perfection. Calibration from Endress+Hauser – let us help you stay in tune! www.us.endress.com/calibration
Endress+Hauser, Inc
2350 Endress Place
Greenwood, IN 46143 Sales: 888-ENDRESS
[email protected] Service: 800-642-8737
www.us.endress.com Fa x: 317-535-8498
New perspectives without the compromise.
Industry-optimized ultrasonic
flowmeter reliably measures biogas
from anaerobic digesters or landfills
The Proline Prosonic Flow B200 is the first true 2-wire,
4-20mA HART®, loop powered ultrasonic flowmeter for
multi-variable measurement of volume flow rate, temperature
and methane content. With the B200, it is now possible –
using precisely measured sound velocity and an integrated
temperature sensor – to simultaneously measure the methane
content directly in the pipe without additional devices. This
one of a kind feature opens up completely new perspectives:
s Continuous, around the clock monitoring of

gas quantity and quality
s Fast and targeted reaction in case of interference
in the fermentation process
s Efficient process control and energy balancing
by calculating additional characteristic values
(Corrected volume, calorific value, energy flow)
www.us.endress.com/prosonic-flow-b200
Endress+Hauser, Inc.
2350 Endress Place
Greenwood, IN 46143 Sales: 888-ENDRESS
[email protected] Service: 800-642-8737
www.us.endress.com Fax: 317-535-8498

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Plan 23 Mechanical Seal Design • Trends In Coriolis & Ultrasonic Flowmeters • SCADA Security

2-Way Hot Water and Electromagnetic Low Flowmeter Non-Contact Ultrasonic

Visit omega.com/sv4000a Visit omega.com/fmg70 Visit omega.com/lvu30

20 Establishing a Mechanical Seal Baseline

48 QUIZ CORNER charles’ law

2 August 2012 Flow Control

Continuous Quality Improvement G R A N D

engaged in a serious pursuit Society of Business Publication

improvement creates an inertia that inevitably leads

us to do and be better. SUBSCRIPTION & REPRINT REQUESTS:

“Viewpoint” editorial; and 2006 “Best Cover” and years, to come. FC

4 August 2012 Flow Control

APPLICATION NOTE: Putting Flowmeters to the Test

6 August 2012 Flow Control

Rotork Names Withers Technical

actuator product lines.

Shanahan Named President of

www.FlowControlNetwork.com August 2012 7

Programmable Logic Controllers Lead I/O Market in 2011

8 August 2012 Flow Control

Industrial Valve Sales To Exceed $55 Billion in 2013

World Industrial Valve and

www.FlowControlNetwork.com August 2012 9

Mergers & Acquisitions

✓ DeZURIK Inc., (www.dezurik.com) a supplier of munici- ✓ Furmanite Corporation (www.furmanite.com), a large

✓ Parker Hannifin Corporation (www.parker.com) has

✓ Kaman Industrial Technologies Corporation (KIT), a sub-

✓ Fluid and metering technologies company IDEX

✓ Oil States Industries Inc., a subsidiary of Oil States

Write in 7 or Request Info Instantly at www.FlowControlNetwork.com/freeinfo

10 August 2012 Flow Control

Write in 8 or Request Info Instantly at www.FlowControlNetwork.com/freeinfo

Part I: Variable-Speed Drive Energy Savings

✓ 50 percent of flow means that the motor/pump operates at

✓ Power consumption is (0.50)3 or 12.5 percent of the power

✓ There is an 87.5 percent energy savings when operating the

Flow Problems? motor/pump with a variable-speed drive at 50 percent of flow.

We Can Help WRONG!!! Give it some thought until next month. FC

David W. Spitzer is a regular contributor to Flow Control maga-

12 August 2012 Flow Control

© 2012 Magnetrol International, Incorporated

Do Your Thermowells Meet the ASME Standard?

Various thermowell process connections and

mowell shank styles. Conveniently, each

14 August 2012 Flow Control

PLASTIC CONTROL VALVES FOR

P.O. Box 938 • Angleton, TX 77516

Write in 10 or Request Info Instantly at www.FlowControlNetwork.com/freeinfo

✓ Provided no fatigue factor for oscillatory stress or stress

✓ Performed the installed natural frequency calculation in a

crude manner without including any effects of foundation stiff-

What Changed in 19.3TW & Why It Is So Much

✓ Failed to address in-line vibration,

✓ Failed to assess oscillatory stress independent of steady

16 August 2012 Flow Control

For more information, contact:

Flow Research, Inc.

Write in 12 or Request Info Instantly at www.FlowControlNetwork.com/freeinfo

18 August 2012 Flow Control