February 2014 PDF

Redefining Pump Control • What Is a Volumetric Flowmeter?
• Closed System Liquid Dispensing
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FEBRUARY 2014 Vol. XX, No. 2

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contents february 2014 | Vol. XX, No. 2
14
61
features
Accuracy Matters
14 By Cleve Nyberg
In today’s business environment, we are constantly confronted
with the bottom line. Energy usage has naturally become a con-
cern along with other overhead costs. As this emphasis on en-
ergy efficiency increases, so too does our dependence on flow
18
61
measurement devices for process energy measurement.
Redefining Pump Control

18 By Kelvin Findlay
You’ve probably heard of BEP before. In fact, you’ve likely
known the Best Efficiency Point has somehow been important
for a while now; but you may not know why it is important or
how to get there. The first thing you need to do is get to know
your pump curves.
Considering the Popularity

22 of Magnetic Flowmeters
By Jesse Yoder, Ph.D.
While the magnetic flowmeter market is a mature and stable
24
61 one, there are some new product developments in the magme-
ter market, and these new developments figure to help gener-
ate continued growth for this technology going forward.
Fluid Handling Safety

24 By Thomas A. Braun
At any given time, there are millions of liquid-filled drums and
IBC totes in circulation around the world, transporting every-
thing from edible oils and flavorings to detergents and solvents
or other hazardous media. Closed system dispensing systems
offer a safe and effective method of transferring these fluids.
Flow Control (ISSN #1081-7107) is published 12 times a year Birmingham, AL 35242 and additional mailing ofices.
by Grand View Media Group, 200 Croft Street, Suite 1, Birming- Subscription Information
ham, AL 35242. © Entire contents copyright 2014. No portion of this publica-
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2 | February 2014 Flow Control Magazine

break through
the
NOISE
Better Signal-to-Noise Ratio Means

Better Level Control Performance
While transmit pulse amplitude (signal size) has helped to make
guided wave radar technology the standard for accurate, reliable level
4.40 measurement, the fact is signal-to-noise ratio (SNR) represents a far
Model 706
SNR more critical indicator of level control performance. For superior SNR in
all process conditions, no other GWR device beats the Eclipse ® Model
1.57 706 transmitter from Magnetrol®.
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signal-to-noise ratio nearly 3 times higher visit eclipse.magnetrol.com or contact
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© 2014 Magnetrol International, Incorporated
28
contents continued
columns
6 VIEWPOINT
the business of ethics
12 APPLICATIONS CORNER
troubleshooting a highly functioning
process unit
28 PUMP GUY departments

calculus gymnastics
8 NEWS & NOTES more choices
for pressure measurement; FCC revises
32 AUTOMATION FILE rules for radar level devices; gahna’s off-
a q&a with the new president of the hart shore oil & gas sector shows promise …
communication foundation
“
36 NEW PRODUCTS
In today’s business environ-
ment, we are constantly con-
37 WEB RESOURCE FILE
fronted with the bottom line. 38 ADVERTISER/
Energy usage has naturally PRODUCT INDEX
”
become a concern along with
other overhead costs. 39 WORD SEARCH
analytical systems
On the Cover: Background image by Ulla Rose/iStock/

ThinkStock; meter image courtesy of Cadillac Meter.
40 QUIZ CORNER
what is a volumetric flowmeter?

Dynamic testing to
ISO/IEC 17025 ensures
accuracy.
FMC Technologies’ accredited Flow Research and Test Center puts every meter
manufactured through the paces, giving you conidence that the volume of
product delivered is accurate. Our experienced technicians perform dynamic
testing of low rates to 6,670 m3h (42,000 bph) andviscosities to 250 cSt;
FMC Technologies Flow
the widest measurement capabilities in the world today. Whether it’s a Research and Test Center
custom ultrasonic or a specialized turbine meter, you know that Smith Meter® is accredited through NVLAP
products from FMC Technologies will perform in the ield as they did in our (NVLAP Laboratory Code 200939-0).
test center. For more information visit www.fmctechnologies.com/labfc
Copyright © FMC Technologies, Inc. All Rights Reserved.
www.fmctechnologies.com

VIEWPOINT
The Business of Ethics G R A N D

GV
V I E W M E D I A G R O U P
A
t the time of this writing, West Virginia’s gov-
ernor, Earl Ray Tomblin, has ordered Freedom
Industries to begin removing the above-ground PUBLISHER
storage tanks and associated piping and machin- MICHAEL C. CHRISTIAN | (908) 507-5472
mikec@grandviewmedia.com
ery at its Charleston chemical facility, which was EXECUTIVE DIRECTOR OF BUSINESS
responsible for a Jan. 9 spill that contaminated DEVELOPMENT
JOHN P. HARRIS | (205) 408-3765
the water supply for an estimated 300,000 West john@grandviewmedia.com
Virginians. And while the investigation to determine EXECUTIVE DIRECTOR OF CONTENT

MATT MIGLIORE | (610) 828-1711
what caused the chemical spill, how much was spilled, and what matt@grandviewmedia.com
the long-term consequences are is ongoing, the initial response MANAGING EDITOR
JAKE MASTROIANNI | (205) 408-3784
by some supporters of the coal industry has been more pushback jmastroianni@grandviewmedia.com
than remorse for the damaged community surrounding the plant. COLUMNISTS
LARRY BACHUS;
DAVID W. SPITZER; JESSE YODER
According to a report by The New York of development and need to be refined to
ART DIRECTOR
Times, West Virginia’s junior senator and better equip our future business and indus- JULIE FLYNN
former governor, Joe Manchin III, attend- try leaders to ethically respond to modern julie@grandviewmedia.com
ed an event sponsored by the Coalition challenges in the face of the temptations MARKETING MANAGER
for Clean Coal Electricity in Washington of increased profits and/or reduced costs. MARY BETH ROMANO
shortly after the spill, where he said, In an article published in Inside Higher SUBSCRIPTION & REPRINT REQUESTS:
“You feel like everyone’s turned against Ed, Terry L. Price frames it well: “It is not flowcontrol@halldata.com
you,” and vowed to continue to fight back enough for business students to hear yet
against proposed new Environmental Pro- again that certain behaviors are gener- Administrative Team
tection Agency regulations on coal. Man- ally prohibited by morality. They must also GENERAL MANAGER
BARRY LOVETTE
chin, a democrat, has also called for a come to see that these prohibitions apply VICE PRESIDENT OF OPERATIONS
repeal of the Clean Water Act on moun- to them even when morality conflicts with BRENT KIZZIRE
taintop mining.1 self-interest, the bottom line, and the inter- GROUP DIRECTOR OF
CIRCULATION & FULFILLMENT
Certainly, the debate for and against ests of investors.”2 DELICIA POOLE
regulation is complex, and there are Ethics in business can often be a murky CIRCULATION MANAGER
ANNA HICKS
strong cases to be made on both sides subject, but if we can address more of our VICE PRESIDENT OF FINANCE
BRAD YOUNGBLOOD
depending on the issue at hand. That missteps in business along the way and
said, in this situation, I think it’s fair to hold ourselves up to a higher ethical stan- EDITORIAL ADVISORY BOARD
Larry Bachus: Bachus Company Inc.
question the idea of taking a stance dard, perhaps we can avoid more of the Gary Cornell: Blacoh Fluid Control
against regulation at a time when hun- catastrophic failures that have recently de- Jeff Jennings: Equilibar LLC
Mitch Johnson: JMS Southeast
dreds of thousands of your constituents bilitated and damaged not only our com- Peter Kucmas: Elster Instromet
are without access to potable water for munities, but also the businesses that Jim Lauria: Water Technology Executive
James Matson: GE Measurement & Control
drinking, cooking, and bathing due to a serve them. FC John Merrill, PE: EagleBurgmann Industries
chemical spill. Steve Milford: Endress+Hauser U.S.
David W. Spitzer, PE: Spitzer and Boyes LLC
In considering the Freedom Industries Thanks for your readership, Tom Tschanz: McIlvaine Company
spill and, in a larger sense, the adversar- John C. Tverberg: Metals and Materials
Consulting Engineers
ial culture that puts industry and regula- — Matt Migliore, Director of Content Jesse Yoder, Ph.D.: Flow Research Inc.
tors at opposite ends of what seems to be Matt@GrandViewMedia.com
WINNER WINNER
a never-ending tug-of-war, I got to think-
ing about the role of business ethics in References
this story. 1. “Chemical Spill Muddies the Picture in WINNER WINNER WINNER
Business schools in the U.S. have a State Wary of Regulations,” Trip Gabriel,
ramped up their business ethics curricu- Michael Wines and Coral Davenport, The
lum in response to corporate wrongdo- New York Times, Jan. 19, 2014. WINNER
ing in recent years. But many of these 2. “How to Teach Business Ethics,” Terry L.
programs are in their formative stages Price, Inside Higher Ed, June 4, 2007.

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THE OUTLOOK | News & Notes
As Technology Brings New Features

to Pressure Measurement, End-Users
Have More Options to Consider
By Jake Mastroianni
T echnology has undoubt-

edly improved the capa-
bility of pressure measure-
security and wireless transmissions of
process data, especially for monitoring
applications, which has led to more us-
ers switching to wireless-enabled pres-
ment instruments in recent sure transmitters.
years, but the selection pro- “We continue to see advancements
cess has grown more com- in the microprocessor technology,” says
Shoker. “These advancements have
plicated with more options to facilitated development of more pow-
choose from. erful and reliable pressure transmit-
As it is with any technology, the goal ters. Leading suppliers in the pressure
is to specify a solution that is both cost- transmitter market continue to leverage
effective and efficient for the application these ongoing technological develop-
under consideration. “The current com- ments to offer customers transmitters
petitive and highly regulated industrial that are increasingly accurate, reliable,
environment demands more efficiency, and functional.”
reliability, and safety than ever before,” Modern electronic differential- While modern pressure transmitters
says Inderpreet Shoker, analyst for ARC pressure systems are capable of can be expensive than the more sim-
Advisory Group (www.arcweb.com). “As eliminating many of the mechanical plistic technologies that came before
issues seen in traditional differential-
a result, users now look for additional them, the capabilities they bring typi-
pressure measurement.
features in their pressure monitoring (Photo courtesy of Endress+Hauser) cally offset the added expense in the
solutions, such as predictive diagnostics long run. For example, Shoker says mul-
and software-based configuration.” range, temperature range, ambient tivariable transmitters can do what once
Pressure measurement technology environmental conditions, overpressure required three devices to accomplish;
has expanded to enable more access to protection, stability, accuracy, and com- measuring differential pressure, gauge
process information through improve- munication protocol.” pressure, and process temperature (in
ments in diagnostics, advanced moni- Shoker says one major recent conjunction with an external RTD or
toring in the health of the device, and breakthrough for pressure measure- thermocouple). Further, many multivari-
monitoring of the process loop. Accord- ment technology was the introduction able transmitters can perform various
ing to Ehren Kiker and Chris Riordan, of WirelessHART (www.hartcomm.org) flow calculations, as well as measure
product managers for Endress+Hauser, and the ISA100 (www.isa100wci.org) level in tanks. Shoker says it is this ap-
Inc. (us.endress.com), some key en- series of standards. The emergence of plication versatility that is driving rapid
hancements in pressure measurement WirelessHART and ISA100 offers end- increases in the popularity of multivari-
technology include improvements in users a reliable and user-friendly way able transmitters.
sensor design—resulting in better re- to deploy wireless field devices, allow- Now that end-users have a wide
sponse times, lower susceptibility to ing what were once hard-to-reach and/ variety of sensor technology options to
condensation, and support for more or stranded assets to be connected to a choose from, the decision on which is
challenging applications—lower power plant asset management system. the best and most efficient becomes
consumption, and innovative platforms, This extended access to wireless more important.
such as electronic differential pressure. technology gives users the opportunity “While it is good to have as many
“Careful consideration of specific to install field devices in measurement features as possible in your devices, it
requirements is crucial to choosing ap- points that were previously not possible is not cost-effective to do so,” Shoker
propriate measurement technology,” due to, for example, the high cost of says. “Therefore, end-users should re-
says Shoker. “Some major consider- wiring or hazardous areas. Encryption view their applications carefully and
ations when selecting pressure mea- and mesh networking technologies have choose pressure measurement tech-
surement technology include pressure eased the concerns of end-users about nologies with specific features that are

crucial to their application.” For exam- trial manufacturing operations. it is important that users consider long-
ple, he says end-users who are monitor- “Although improving profitability re- term cost of ownership and return-on-
ing pressure in hazardous locations or mains a high priority for all companies, investment rather than just initial cost.”
face certain space or wiring constraints when faced with tight budgets, many
will want to make sure they are placing tend to focus on short-term savings. Jake Mastroianni is the manag-
these factors at the top of their priority Trying to lower the project cost in this ing editor of Flow Control magazine
list when specifying a device. situation, engineers tend to choose and FlowControlNetwork.com. He
An advanced feature that is push- cheaper technology that may not offer can be reached at JMastroianni@
ing the future of pressure transmitters benefits that help them save money in GrandViewMedia.com or 205 408-
is predictive diagnostic capability. “Pre- the long run,” says Shoker. “Therefore, 3784.
dictive diagnostic tools are giving [end-
users] greater flexibility for monitoring
process conditions and allowing users
to be more proactive in their mainte-
nance activities rather than being purely
reactive,” says Kiker & Riordan.
Looking into the future, Shoker ex-
pects advancements in sensor and mi-
croprocessor technologies will continue
to improve the accuracy and reliability
of pressure measurement devices. He
also expects advances in wireless pow-
er transmission to increase the accep-
tance of wireless technology in indus-
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www.flowcontrolnetwork.com February 2014 | 9

THE OUTLOOK | News & Notes
trendlines
Texas Leads the Way as US Oil & Gas Projects Rise

from $288B in 2013 to $379B in 2014
T here are 6,322 active U.S. indus-
trial projects totaling $379 billion
that are scheduled to begin construc-
tion in 2014, according to Industrial
Info’s Industrial Project Database (www.
industrialinfo.com).
At the end of January 2013, about
$288 billion worth of industrial projects
were scheduled to begin construction
for the remainder of the year.
Industrial Info’s database shows that
there are more than 780 projects total-
ing about $71 billion, with Texas having
the most, accounting for 19 percent of Industrial Project Construction (Industrial Info Resources)
the value of industrial projects sched-

uled to begin construction in 2014. Rounding out the top 10 are Indi- year, with 75 projects totaling $24 bil-
The second largest state is Louisi- ana, Illinois, Pennsylvania, Ohio, Or- lion, passing the Chemical Processing
ana, with 379 projects totaling $45.7 egon, Alaska, and Nevada. and Power industries as the top industry
billion. California is third largest, with The Oil & Gas production industry for planned projects in Texas, according
338 projects totaling $30.5 billion. has grown dramatically over the past to Industrial Info.
Ghana’s Offshore Oil & Gas Sector Shows Promise

A s Ghana’s Jubilee offshore oilfield
approaches peak output of 120,000
barrels per day, interest in the country’s
the end of 2013. According to Tullow’s
H213 operational update, output was
averaging 110,000b/d and remained
than the 100,000b/d initially planned)
and is due to come online by late-2016.
This increased upstream activ-
untapped deepwater potential remains on track to reach the plateau rate of ity will support rising production, which
high, according to a report by Business Monitor expects will
PaulFleet/iStockPhoto/ThinkStock
Business Monitor (www.busi- grow from around 110,000b/d

nessmonitor.com). in 2013 to 243,000b/d by the
While Ghana’s second end of its forecast period in
major oil development proj- 2022. However, these volumes
ect, TEN, is expected to come assume the contribution of new
online in late 2016, Business supplies beyond fields currently
Monitor says that without a approved, namely liquids from
positive investment decision Eni’s Sankofa development.
on a number of promising New production will be
new discoveries under ap- important, in line with a strong
praisal and/or new finds, the macroeconomic picture; oil de-
country’s overall output may mand is expected to rise, which
begin to gradually slip by the will in turn reduce the amount
end of the decade. of oil available for export, hitting
A few highlights from the Business 120,000b/d by the end of the year. earnings. However, with added supplies,
Monitor report include: In another sign of strength for should Ghana fail to invest in its down-
After a troubled start, output from Ghana’s oil sector, regulatory approval stream, it will continue to rely on expen-
the Tullow Oil-operated Jubilee field is was given to the Tullow-led Tweneboa- sive imports of refined products from
on track to reach the target production Enyerna-Ntomme project (TEN), which abroad as the ageing refinery at Port
rate of 120,000 barrels per day (b/d) by will see peak output of 80,000b/d (less Tema falls short of domestic demand.

trendlines
Developing Regions Drive Strong Growth for Water

Treatment Equipment Worldwide
W orld demand for water treatment
equipment is expected to grow
6.9 percent per year to $53.4 billion
ported by improved access to treated
drinking water and sanitation facili-
ties, particularly through greater use
in Japan, North America, and Western
Europe, as demand for membrane
systems and disinfection equipment
in 2017, according to a report by the of filtration and membrane systems. in these regions will be supported by
Freedonia Group (www.freedoniagroup. Expanding manufacturing and indus- continued efforts to reduce chemical
com). Developing parts of the world— trial activities requiring water treatment use by replacing chlorine and other
the Asia/Pacific and Africa/Mideast equipment, such as membrane sys- chemicals with water treatment equip-
regions, Eastern Europe, and Central tems and disinfection equipment, will ment, as well as an ongoing rebound in
and South America—are expected to also promote growth in these regions. manufacturing output after the 2009
show strong growth, with gains sup- Freedonia predicts more modest gains global recession.
2014 North American Industrial Project Start

Projections Up $96B from 2013
A s the new year kicks off, Industrial
Info Resources (www.industrialinfo.
com) is tracking 7,760 projects with
ect activity will actually take place due
to project fallout, Industrial Info says
the higher anticipated dollar amount
ing (metals and oil sands) projects in
Canada. By far the highest-value proj-
ect set to kick off in 2014 is Gulf Coast
a combined total investment value between years is quite substantial. LNG Export LLC’s four-train LNG produc-
$575.8 billion that are planned to kick Industrial Info says some of the largest tion and export terminal at the Port of
off in 2014 in North America. This com- of these projects are for construction of Brownsville in Texas. The project, which
pares to about $480 billion that were liquefied natural gas (LNG) production has a total investment value of $8.5 bil-
planned to kick off in 2013 at this time and export terminals along the U.S. Gulf lion is expected to kick off in mid-2014,
in 2012. And while not all of this proj- Coast, and large hydropower and min- with completion set for 2018.
best practices & standards
FCC Revises Rules Regulating Frequency Bands for

Radar Level Measurement Devices
T he U.S. Federal Communications Commission (FCC,
Leung Chopan/iStock/ThinkStock
www.fcc.gov) has adopted rules geared specifically

to level probing radars (LPRs) that allow these devices to
operate anywhere in the country without a license. The
Measurement, Control & Automation Association (MCAA,
www.measure.org) worked with the FCC to provide informa-
tion to the technical office within the FCC, which crafted a
Notice of Proposed Rulemaking in 2012. The FCC action
amends the existing rules to account for LPR special techni-
cal characteristics, which posed previous obstacles to FCC
approval. Specifically, the order modifies Part 15 of the FCC
rules for level probing radars to operate on an unlicensed
basis in the 5.925-7.250 GHz, 24.05-29.00 GHz, and
75-85 GHZ bands, and revises the measurement proce-
dures to provide more accurate and repeatable measure-
ment protocols for these devices.

APPLICATIONS CORNER | Process Instrumentation
The Things You Don’t Know

Troubleshooting operational issues on a highly
David W. Spitzer functioning process unit
W
ere you ever proud of what you didn’t know? cially if one has the confidence and ability to solve the few
At a plant I worked at earlier in my career, the problems that occasionally arise over the years.
previous instrumentation engineer designed the in- One of the two operational problems was that a particular
strumentation in one of the units. While anyone can find a few flowmeter measured about 10 percent lower than it should
things to disagree with on any large project, my predecessor have been; and this had been the case for years. The opera-
and the people in other disciplines designed the unit quite tors questioned the measurement, and sure enough docu-
“
well—so well that the unit rarely exhib-
ited operational problems. Pleased to not
have problems with the unit, I was secretly Many problems can be solved using basics—
proud to not know the details associated
”
with the unit.
and many basics are comprised of relevant
Other than a few periodic process and knowledge and the skill to use it.
measurement upgrades, I recall being
aware of only two operational problems
during the 15 years I worked in that plant—both related to mentation and process measurements bore them out as cor-
flowmeters. There may have been a few other minor issues rect. Installing a new flowmeter (using the same technology)
and/or questions, but certainly nothing of significance. Learn- in a different orientation solved the problem.
ing about the unit in detail simply was not necessary—espe- Problem No. 2 was being played out when I started work-
ing at the plant. It was more complicated and will take more
than one article to describe.
Many problems can be solved using basics—and many
basics are comprised of relevant knowledge and the skill to
use it. Knowing instrumentation, how to use plant measure-
ments, and having the ability to understand Process and
Instrumentation Drawings (P&ID), loop drawings, heat and
material balances, operating procedures, safety procedures,
hazard reviews, pump curves, etc., can provide you with the
tools to effectively analyze operating problems.
Are your skills in order? Can you be proud of something
that you don’t know?
Flow Problems? Look for more on “Problem No. 2” in the March issue. FC
David W. Spitzer is a regular contributor to Flow
We Can Help
Control magazine and a principal in Spitzer and Boyes, LLC
offering engineering, seminars, strategic, marketing con-
sulting, distribution consulting and expert witness services
>> Troubleshoot Problem Flow Measurements for manufacturing and automation companies. Spitzer and
>> Assess Billing Flowmeter Accuracy Boyes is also the publisher of the Industrial Automation
Insider. David has more than 35 years of experience and
>> Close Plant and Water Balances
has written over 10 books and 300 articles about flow
>> Improve Flowmeter Accuracy measurement, instrumentation and process control.
>> Select and Specify Flowmeters
>> Train Your People FLOWSTREAM Find related content @
flowcontrolnetwork.com
WE KNOW FLOW! David W. Spitzer | Flowmeter |
www.spitzerandboyes.com • 1.845.623.1830 Process Instrumentation
APPLICATION ISSUES | Flow Measurement
ACCURACY MATTERS
Considering flowmeter performance in the light of extreme
low-end velocities in energy measurement By Cleve Nyberg
I n today’s business environment, we are constantly con- flow computers to make calculations,
provide linearization adjustments, and
fronted with the bottom line. Energy usage has naturally even further reduce temperature error
become a concern, along with other overhead costs. As by zeroing out error in the operating dif-
the emphasis on energy efficiency increases, so too does ferential span of the application. With
our dependence on flow measurement devices for process OIML R75 compliance, flow computers
can subsequently provide reading accu-
energy measurement. racy to +/- 0.1 percent rate, making
The demand for energy conservation cation with matched pair temperature it a rather accurate component in the
throughout society requires end-users sensing technology accurate to +/- flowmeter application under consider-
and industries alike to measure energy 0.01 percent of span (typically 200 F) ation here.
use. For heating and chilled water ap- or 0.02 F. The combined accuracy of
plications, this requires the installation both sensors would be approximately Flowmeter Accuracy
of flow and temperature measuring de- 0.04 F. With a differential temperature Now let’s consider the flowmeter tech-
vices tied to a BTU computer. From this of 10 F, the accuracy would be approxi- nology. Within the standard range of
information, the end-user can assess mately +/-0.4 percent. This accuracy, optimal flow velocity, you can expect
where and how energy is being con- even in a worst-case scenario, is bet- the flowmeter technologies we will con-
sumed, and then take steps to improve ter than some widely used flowmeter sider here to be accurate to +/- 0.5
efficiency. technologies—as you will see the para- percent of rate or reading. However,
Extreme low-end flow velocities are graphs to follow. (NOTE: Temperature this specification does not reflect the
becoming more prominent in certain sensor accuracy will degrade as differ- range in which the meter will actually
applications as a product of the drive for ential temperature is reduced.) be operating in the field, or straight-run
energy efficiency. And while such tech- pipe requirements. To achieve +/- 0.5
nologies as variable-frequency drives Flow Computer Accuracy percent of accuracy, most flowmeter
(VFDs) and modulating flow valves are Today’s advanced technology allows technologies considered will require a
enabling end-users to fully developed flow pro-
optimize flow in their hot/ file, which usually means
chilled water systems, that they need sufficient
do we really understand straight-run pipe up and
how these lower flow downstream.
velocities are impacting In addition, the flow-
flowmeters? Let’s con- meter accuracy state-
sider an application (hot/ ments are generally as-
chilled water) and its sociated with a specific
flow measurement com- turndown value. This
ponents (a matched pair indicates the lowest ve-
of temperature sensors, locity at which the me-
a flow computer, and a ter is able to maintain
flowmeter). What is the its accuracy statement.
single most limiting fac- For example, if a meter
tor on the accuracy of has a maximum velocity
the system? of 20 ft./s and performs
accurately over a turn-
Temperature down of 10-to-1, then
Sensor Accuracy A magnetic flowmeter in water service. (Photo by Cadillac Meter)
you can divide 20 by 10
Let’s consider an appli- to find that the minimum

velocity at which the meter will uphold its accuracy state-
ment is 2 ft./s. Below this minimum velocity, the flowmeters
will have another accuracy specification, suggesting a fixed
error that is independent of the actual flow velocity. This
means that as velocity drops farther and farther below the
turndown minimum, the meter becomes less accurate.
Mechanical meters using moving parts, such as tur-
bines (typically +/- 0.5 percent of reading over a 20-to-
1 turndown) and paddlewheels (typically +/- 0.75 percent
of reading over a 10-to-1 turndown), will have a point at
which the meter ceases to function altogether. As the mov-
ing parts foul and wear over time, this point of inoperability
will occur at higher and higher velocities.
Vortex meters (typically +/- 0.8 percent of reading over
a 25-to-1 turndown) will also cease to operate at low flow-
rates. When velocity is reduced to a point where vortices
are no longer created, the meter will no longer sense flow.
Magnetic flowmeters (typically +/- 0.5 percent of read-
ing over a 30-to-1 turndown) are much more capable of
maintaining accuracy at low flow velocities, and they will
even provide accurate measurements under less-than-ideal
flow profile conditions. That said, most magmeters will also
struggle to deliver accurate measurements at low flow ve-
locities.
Measuring Extremely Low Flowrates

Even if you have the most accurate flowmeter on the mar-
ket, does the range of flow velocities it was designed to
measure align within the extended range your system is
now operating in? If not, what happens below the technol-
ogy’s threshold?
A flowmeter’s operating range can be put it into one of
three categories, which are defined by an associated error
expressed as a percentage of reading or measured value.
Flow Measurement: The accuracy standard of flow
measurement devices is +/- 5.0 percent. While we now
know that the flowmeter itself is not the only factor in this
error percentage, for the sake of clarity and round numbers,
we’ll stick with +/- 5.0 percent.
Flow Indication: This category encompasses flowme-
ters with accuracies ranging from +/- 5.0 percent to a worst
case of +/- 50.0 percent. This range is admittedly vast, but
the reason for detecting flow will depend on the application
and the end use of the data collected.
Flow Switch: Any error rate above +/- 50 percent will
classify a device as a flow switch. Essentially, this provides
an on/off indication, which in many cases is used to start/
stop pumps so they don’t run dry.
Devices in all three categories can offer valid and use-

ful information, depending on the application. However, in
regards to collecting data for the purpose of determining en-
ergy usage and efficiency, it is critical to remain in the flow
measurement category. That said, here we will show how
some flowmeter technologies will be hard pressed to uphold
+/- 5.0 percent accuracy when confronted with low flow

APPLICATION ISSUES | Flow Measurement
velocities common in today’s pumped meet these needs. As a result, it is cus- ing valves to be employed to optimize
water systems. tomary for VFDs and flow control divert- the electricity demand required to move
Reducing Energy Usage

in Pumped Water Systems
Prior to the use of VFDs and modu-
lating flow valves, the majority of
hot/chilled water systems operated
in a pump on/off mode with paral-
lel pumping systems used to meet
the demands of the application.
Concerns about excessive electric-
ity usage were minor, so the pumps
would run up their performance
curves, drawing as much electrical
current as they needed to meet
the upstream pressure drop and
maintain flow. As an initial effort to
abate this, VFDs were introduced
in the 1980s to bring down energy
costs and provide just enough flow
to satisfy downstream demand.
Subsequently, a new generation
of products was created to meet
the point-of-use requirements, Figure 1. When flowrates are set below 1 ft./s, it is important to consider how this
will impact the accuracy of the flowmeter.
while reducing the energy used to
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Pressure Transducers,
water. This has, in turn, impacted the flow conditions in both
Transmitters and
new and retrofitted applications. Load Cells
Before VFDs and automated diverting valves, the velocity
range with pumps operating in an on/off mode was 1–15
High Speed USB Output
ft./s. But today, the velocity range is 0.1-15 ft./s, or a de- Pressure Transducer
crease in flow velocity by a factor of 10. Connect Directly to Your Computer
So, with this extended flow range brought to light, it is
important to consider how flowmeters will respond when op- PX409-USBH Series
erating at low flowrates. Starts at
$545
Performance Concerns
To illustrate the answer to this question, we will examine
three popular flowmeter technologies (dual-element tur-
bine, dual-electrode insertion magmeters, and full-bore
magmeters). These meters are compared in Figure 1, which
shows the error percentage maintained between +/- 5.0
percent of rate or reading. It is interesting to see how each
s 1000 Readings/Second
meter responds as we move farther down the extended
s Micro-Machined Silicon Sensor
velocity range in this application scenario.
s 316L SS Wetted Parts Visit
As you can see, the meters increasingly lose accuracy
toward the lower end of the operating range, with some
s High ±0.08% BSL Accuracy omega.com/
struggling to provide sufficient measurements through half
s Free Software Included px409-usbh
of the new extended operating range. While the dual-elec-
trode insertion magmeter still has an operating accuracy
Rugged Solid State Pressure Transmitters
specification through the extended range, its logarithmically Small Lightweight Package
declining accuracy makes it a flow indicator at the lower end
of the new range. Even the traditional full-bore magmeter
becomes a flow indicator at the lower end, making a bold
statement on how difficult it can be to make an accurate PX170 Series
flow measurement at the low-end velocities experienced Starts at
$250
when VFDs and flow control diverting valves are employed
to optimize the electricity demand required to move water.
In the light of the information presented here, it is impor-
tant for end-users who employ VFDs and diverting valves for Visit
hot/chilled water applications to consider how this installa- omega.com/
tion will impact flowmeter performance. FC px170_series
Cleve Nyberg has 25 years of process control experi- Subminiature Tension or
ence with a strong background in both analytical and flow Compression High Accuracy Load Cells
instrumentation. He worked in the field as an application
Standard and Metric Models
consultant, product sales manager, and regional sales
manager for two international instrumentation companies
prior to joining Cadillac Meter, also known as Central
Station Steam Company. Mr. Nyberg is currently responsi- LCFD/LCMFD Series
ble for product development and technical sales for Central All Models
Station Steam Company. Mr. Nyberg can be reached at $760
cnyberg@cadillacmeter.com or 503 624-6331.
www.cadillacmeter.com
Visit omega.com/lcfd
FLOWSTREAM
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Flowmeter Accuracy | Flowmeter Turndown | © COPYRIGHT 2014 OMEGA ENGINEERING, INC ALL RIGHTS RESERVED
®
Low Flow Velocity | Variable Frequency Drive


BEST PRACTICES | Pump Reliability & Maintenance
REDEFINING
Pump Control
The secret to minimizing your maintenance requirements By Kelvin Findlay
R ather than learning how to optimize pump performance

and reliability, many pump operators limit their job to
hitting the power switch. Why? Because that is how they are
What would happen to your main-
tenance budget if you weren’t replac-
ing bearings and seals on each of your
pumps every six months? How much
trained. And if they seek out more training, either the budget are you spending on replacing these
won’t allow it, or there is little support. parts unnecessarily?
You can translate this to your num-
Maybe that’s one of the reasons keep your pump running at or near the ber-crunching superiors as a longer
so many pumps vibrate, are noisy, and BEP. So pump control and operation is MTBF. It also means a positive Return
ultimately spend so much time in the not just about turning pumps on and off, On Investment (ROI) for things like prop-
maintenance shop. Just for fun, look but rather running pumps efficiently. By er training, equipment, and making any
up your Mean Time Between Failure doing this, your pump and its few com- necessary changes to your pumps to
(MTBF) numbers to see what equipment ponents will last a long time—some- get them running optimally.
is driving the statistic. For too many, the thing in the 10 to 20 year range.
answer is pumps. How to Achieve Best
The reality is your pumps and their Efficiency
relatively few parts are designed to You’ve probably heard of BEP before.
last 10–20 years. The manufacturers In fact, you’ve likely known the Best
detail this information in their speci- Efficiency Point has somehow been
fication sheets. So are they lying, or important for a while now; but you
is there something they know that we may not know why it is important or
don’t? The answer is in plain sight, how to get there. The first thing you
and you can find it by simply reading need to do is get to know your pump
your pump owner’s manual. curves.
You should have received a per-
What the Owner’s Manual formance curve specific to your pump
Is Saying when it was first shipped to you—
Your owner’s manual says things like, whether it is a centrifugal or a positive
“Make sure your NPSHa is higher than displacement pump. The curve details
your NPSHr.” Or it might read, “Never a few things and, in the case of a cen-
restrict the flow on the suction side trifugal pump, should look like Figure
of your pump” or “Don’t operate the 1. The pictured curve shows us:
pump with the discharge flow shut off.” The differential head (pressure)
It’s also going to contain your pump that your pump should produce (y
curve and plenty of warnings about axis)
bearing and seal failure, shaft deflec- Flow rates that correspond with
tion, and cavitation when the pump Digital pressure gauges on the suction and the differential head (x axis)
is not operated at its Best Efficiency discharge nozzles of the pump give the Efficiency of the pump (in green)
operator visibility into how the pump is
Point (BEP). Net Positive Suction Head required
operating.
What your owner’s manual is try- (NPSHr) (in purple)
ing to tell you is that you need to Impeller size (centrifugal pumps)

(in black) easier to read, much more reliable, will each pump, however, is the single best
Horsepower of your motor (in blue) last much longer, and can send outputs thing you could do for your pump opera-
RPMs of the motor (top right) to your control system. Adding a little tors and your maintenance budget.
Size of the pump casing—top left. automation will aid your pump operators
in keeping your pumps near BEP. Those What Happens When My
The first four bullet points are your who use analog pressure gauges find Pump Produces Too Little
four main pieces of information. You’ll they cannot leave them on the pump Differential Head?
want to watch these closely. The next very long, as they quickly wear out re- There are really two scenarios here;
two bullet points (impeller size and sulting in an unmonitored pump. Install- either the suction or the discharge
horsepower) are fixed, but changeable ing a pair of digital pressure gauges on pressure is lacking. Your digital pressure
based on your needs. The final two are
fixed.
Make sure you follow the curve that
matches your impeller size. This will
show you exactly where on the perfor-
mance curve your pump is operating at
any given time.
The relationship between differential
head and flow is the most basic concept
on the pump curve—more head equals
less flow and vice versa. As head and
flow vary, the pump’s performance will
follow the curve relative to efficiency,
suction head requirements, and the
needed horsepower. Again, match your
impeller size to the proper curve and
you can track your pump performance.
BEP is indicated where the curve in-
tersects with the best possible efficiency
on your graph. For most pumps, this is
approximately 85 percent of maximum,
or shut-off head. To keep your pump at Together, we can help you get the most
or near BEP, the best thing you can do out of your process.
is train your pump operators to monitor
the differential head. Set both high and Our after-sale support team is always on-call to help you streamline
low parameters of acceptable opera- your installation, setup or field calibration. That’s the Porter Promise.
tion. The differential head is monitored Here’s what process industry professionals say:
using two pressure gauges—one on the “When I use Parker Porter products based on the selection criteria
suction nozzle and another on the dis- provided, I don’t have to worry. It always works!”
charge nozzle.
“An actual person is ready to help – priceless in this industry!”
Both pressure gauges are necessary.
The one at the suction nozzle is the more To ensure peace of mind and process reliability, visit us today at
important of the two as it helps ensure PorterInstrument.com.
that enough energy is coming into the
pump. Too little suction pressure results
in severe pump damage—ranging from
broken seals and worn bearings to cavi-
tation.
The gauge at the discharge nozzle is
useless by itself. But when used togeth-
er with the suction gauge it provides the
differential head measurement and is
useful for spotting downstream issues
within the pump system.
Digital pressure gauges are highly
recommended because they are much

FLOW PRACTICES
BEST | Pump Reliability & Maintenance
UPDATE continued
This can happen if your

operator is draining a tank
and the level gets too low. It
also happens naturally over
time as build-up inside the
suction pipes restricts flow to
the pump, or suction-side fil-
ters gradually clog.
The only way to fix this is to
increase the energy, or suction
head, coming in to the pump.
However, there are a number
of ways to do so. Your opera-
tor can make sure that all the
valves and suction pipe are
completely open. He/she also
needs to check all suction fil-
ters or strainer baskets to make
sure they are clean. If there is
no quick way to increase flow
to the pump, you can refill the
suction tank or use a variable
frequency drive (VFD) to slow
This pump performance curve highlights the various data points available. When used
with the differential pressure reading from the pump, the performance can be tracked and the speed of the pump.
ultimately kept at the Best Efficiency Point. You may need the engi-
neer to install a booster pump
gauges will tell you which is the case. between the suction tank and
the pump. Your engineer can also have the suction side of the
Starving Your Pump: pump re-piped with oversize pipe and long radius elbows. Im-
If you don’t have enough pressure at the suction nozzle of proper plumbing can reduce the suction head. For example,
your pump, the pump is starved. In other words, you don’t you should avoid filters on the suction side of a pump. Make
have enough energy coming into your pump. As you look sure you use shut-off valves and not control valves. Use 45
at the differential head on your pump curve, you’ll notice it degree elbows instead of a 90 degree elbows.
drags the performance to the right of BEP.
This will be indicated on both your suction and discharge Enough Suction Pressure, Not Enough
gauges. If you have a flowmeter installed, you’ll also notice Discharge Pressure
reduced flow. If you have enough energy coming into your pump, but
When your pump is starved, there are a few bad things your discharge pressure is inadequate, then the problem
that happen. You’ll notice your is completely different. Your
pump vibrating loudly as va- differential pressure will also
por bubbles are formed inside be inadequate, and drag your
your pump. These bubbles pump to the right on the per-
form and collapse as they formance curve.
travel from low to high-pres- In this case, there is too lit-
sure zones inside the pump tle downstream resistance and
casing. This is called cavita- the pressure inside the pump
tion, and a starving pump is casing (or volute) becomes
the most common cause. imbalanced. This causes the
The energy from the im- entire shaft and impeller as-
ploding bubbles is strong sembly to deflect to one side,
enough to create cavities on resulting in rubbing and scrap-
the surface of the impeller Two digital pressure gauges show the suction (left) and ing where tolerances are very
blades. The shock waves from discharge (right) pressure readings in feet of water, or tight inside the pump. This is
the cavitation wreak havoc on head. To graph this pump’s performance, all the operator called shaft deflection. The
your bearings and seals caus- must do is subtract the left reading from the one on the impeller can scrape the pump
right for differential head.
ing pre-mature failure. casing, and the mechanical

FEBRUARY 2014
SOLUTIONS for FLUID MOVEMENT,

MEASUREMENT & CONTAINMENT
OEM / System
Integrator
OEM Special
Supplement Highlights
Case Study: Pre-engineered
refueling systems for aircraft
and heavy-duty construction
equipment . . . . . . . . . . . . . Page 2
Q&A: An industry insider offers

keys to OEM and System Integrator
success . . . . . . . . . . . . . . . Page 6
Up Close: Trigg Technologies’

system for custody transfer of liquid
hydrocarbons . . . . . . . . . . . Page 10
Showcase: Component solutions for

OEMs & System Integrators . . Page 11
OEM / SYSTEM INTEGRATOR NOTEBOOK | Welcome
Welcome to the
OEM / System Integrator—
Highlighting the Importance of
Quality and Balance
s we present the third edition of Flow
A
on the keys to success for OEMs and
Control magazine’s OEM / System system integrators (page SS-6).
An overview of Trigg Technologies’
Integrator supplement, I’m beginning to pick
Lease Automation Custody Transfer
up on themes that are common among the (LACT) system, which is designed to ac-
folks I’ve been speaking with who do busi- curately facilitate the transfer of liquid
ness in this world. Key among them is the hydrocarbons between buyer and seller
drive for quality and balance in the technol- (page SS-10).
ogy selection process.
As you consider your system de-
As OEMs and system integrators, On the following pages you will find: sign process, it is important to carefully
your biggest concern is often the reli- A case study showcasing how a consider the technology suppliers with
ability and efficiency of the devices sliding vane pump is providing reliable whom you choose to partner. The range
“
being used to realize your of technology solutions on
larger vision. That is, are the the market today is vast,
devices integrated into your
At the same time, over-specifying and the success of your sys-
system going to be able to the system is also a key concern. tem will ultimately rely on
reliably stand up to the con- While reliability supersedes all, the component technologies
ditions of the applications
cost is always an important fac- it is built upon. The following
they serve. pages provide some insights
At the same time, over- tor. Ultimately, the aim is to strike on the characteristics you
”
specifying the system is also the perfect balance between reli- should look for in technolo-
a key concern. While reliabil- ability, efficiency and cost. gy supplier partners, as well
ity supersedes all, cost is al- as several examples of how
ways an important factor. Ul- OEMs have leveraged com-
timately, the aim is to strike the perfect service in several unique refueling sys- ponent technologies to the advantage
balance between reliability, efficiency tems for aircraft and heavy-duty con- of their systems. FC
and cost. struction equipment (page SS-2).
With this sentiment in mind, the fol- A Q&A with David Nystrom, gen- Thanks for your readership,
lowing pages include some interesting eral manager of TSi Power Products, a
content that aims to shed light on how Control System Integrators Association — Matt Migliore
you can strike this balance in your sys- member company. Mr. Nystrom pro- Director of Content
tems designs going forward. vides an industry insider’s perspective Matt@GrandViewMedia.com
SS-IFC February 2014 Flow Control Magazine

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OEM / SYSTEM INTEGRATOR CASE STUDY | Pumping Systems
A DIFFERENT
Kind of Fuel Pump
Pre-engineered refueling systems for aircraft and heavy-duty
construction applications By Matt Migliore
and overseas. The company’s avi-

ation fueling product line is based
on a system architecture called
MARS (Modular Aircraft Refueling
Systems). Each MARS Module is
designed to perform specific func-
tions and is interoperable with all
other MARS Modules. As customer
requirements expand and evolve,
additional MARS Modules may be
added to provide a fully scalable
solution.
The MARS solution is used for
bulk aviation fuel transfer from
barges to platform operating tanks,
as well as dispensing directly into
helicopters on offshore rigs. Mil-
lennium Systems is also expanding
the sale of its Rooftop Helifuel Sys-
tems for hospitals and emergency
medical service providers.
The MARS solution relies heavily
Millennium Systems MARS Module refueling system is based on Blackmer positive-
displacement pumps, serving applications in commercial, military, and government on Blackmer (www.blackmer.com)
applications. sliding-vane pumps. For example,
the MARS Rooftop Helifuel System
Application: Aircraft Refueling System consists of a Blackmer GX Pump installed at ground level in a
Millennium Systems International, LLC, is a Maryland- MARS PFT (Pump & Filter) Module, which pumps jet fuel up
based company dedicated to providing total system solu- to 14 stories to a MARS RDS (Remote Dispenser) Module.
tions to customers involved with the storage, transfer, mea- Current users of these systems include University of Wisconsin
surement, control, and automation of bulk liquid products. Health, Duke Hospital (NC), D.C. Children’s Hospital, Fairfax
One of the applications Millennium Systems has success- County Hospital (VA), St. Mary’s Hospital (CO), Orlando Health
fully targeted is aircraft refueling. (FL), and others.
Millennium Systems (www.millenniumsystemsintl.com) MARS Helifuel Systems have also been used to support
designs and builds aviation refueling systems for a range of the airborne law enforcement community, with installations
commercial, military, and government customers in the U.S. at multiple sites for CHPS (California Highway Patrol), Las Ve-
SS-2 February 2014 Flow Control Magazine

gas Municipal Police Dept.,
Anaheim Police Dept., Or-
ange County Fire Dept., Va.
Beach Police Dept., Mary-
land State Police, and oth-
ers throughout the U.S.
“We recently supplied 22
“
Like Millenium Systems’ MARS
Blackmer sliding-vane pumps.

The FIMAX cabin is designed for
yard. After completion, the
system is disassembled and
solution, Pernin’s refueling system, shipped with all of the pip-
called the FIMAX cabin, features ing and wiring in conduit in
a container with the MARS
Module and then ship the
tanks on flat racks. Upon
Blackmer GX2 pumps driven
large machines used for building, arrival, Millenium techni-
by diesel engines in mobile construction, earthmoving, civil cians supervise the re-
trailers with filters, meters, engineering, and mining in diffi- assembly of all piping and
and hose reels to Amazon. wiring. “A recent installation
com for emergency diesel
cult markets and areas where the in Gambia (West Africa)
fuel transfer,” says Gordon very poor quality of fuel is a major took five days to complete,”
”
Johnson, president of Millen- issue that causes costly failures says Johnson. “Any other
nium Systems. “This is an- method would have taken
and breakdowns.
other growth market we have five months.”
identified for the future.”
Another MARS product being promoted by Millennium Application:
Systems is the MARS Pre-Fabricated Fuel Farm. This product Construction Equipment Refueling
consists of a MARS Module, which is pre-piped and pre-wired Pernin équipements (www.pernin.fr) has successfully deployed
to multiple 15,000 USG fuel storage tanks in Millenium’s its latest-generation fueling system for applications involving
VK Series Flow Switch

Low cost
Long term stability
Small size for easy installation
Pipe sizes from ½” through 6”
Custom set points
VVX Vortex Flow Meter

No wear
Multiple signal output options;
digital or analog versions
Integrated temperature sensor
Sealed electronics prevent electrical shorts
VMZ Magnetic Inductive Flow Meter

Straight through pipe =
no pressure drop
No moving parts = no wear
Small footprint
1% accurate
Low Cost
Sika฀USA,฀Inc.฀•฀Ph:฀(262)฀886.2695
www.sika-usa.com฀•฀jb@sika-usa.com
Write in 22 or Request Info Instantly at www.FlowControlNetwork.com/freeinfo Write in 23 or Request Info Instantly at www.FlowControlNetwork.com/freeinfo
www.flowcontrolnetwork.com February 2014 SS-3

OEM / SYSTEM INTEGRATOR CASE STUDY | Pumping Systems
construction equipment in North Africa—where dirty fuel is a big

problem. The system is essentially a big fuel filter that is used to
ensure clean fuel for on-site construction equipment.
Like Millenium Systems’ MARS solution, Pernin’s refueling
system, called the FIMAX cabin, features Blackmer sliding-
vane pumps. The FIMAX cabin is designed for large machines
used for building, construction, earthmoving, civil engineer-
ing, and mining in difficult markets and areas where the very
poor quality of fuel is a major issue that causes costly failures
and breakdowns.
The FIMAX system enables fuel polluted with particles and
water to be sufficiently purified and delivered at high flow-
rates. The FIMAX system supports the following processes:
The unloading of delivery trucks to storage tanks with
filtration of particles without water separation;
Transfer from the storage tank to the tank of the ma-
chine, or to another storage tank, with separation of
water and filtration of particles; and
Fueling from the storage tank with particle filtration
and separation water.
Pernin équipements FIMAX refueling system is specially

designed to enable the transfer of fuel in extremely harsh
applications where particle contamination is a trouble-
some issue.
The FIMAX system is equipped with:

Filters for filtration of particles (25 mm)
Water separator and coalescer
Electrical pumping set with Blackmer model TXD 2.5”
pumping system
Positive-displacement meter with mechanical register
with weights and measure accuracy
Pneumatically actuated ball valves
External control panel
External galvanized steel grid to prevent the cabin from
unintended use
The Blackmer sliding-vane pump is the heart of the transfer

function of the FIMAX fueling cabin, enabling high suction

capabilities for petroleum products with various difficult con- proven reliability,” says Jean-François Pernin, president and
ditions, such as: general manager, Pernin équipements. “The pumps are also
Products in underground storage tanks; configured to ensure the meter will never overflow.”
High product vapor pressure under warm atmospheric The Blackmer pumps have been serving for two years
temperatures (various liquids, such as fuel oil, Jet A1, in a variety of heavy-duty applications, with more than 20
GNR, diesel, kerosene); and cabins currently in operation and no complaints from the
High discharge pressures based on the fouling of filters end-users.
cartridges. Pernin is currently considering the FIMAX cabin in any ap-
plication where the quality of fuel is an issue and the user
The pumps also provide extreme reliability, which is a neces- cannot afford to stop the duty of the machine. One of the next
sity since the FIMAX cabin is frequently deployed in harsh, prospective applications is for the fueling of harbor cranes in
difficult-to-reach environments where no maintenance facili- African countries. FC
ties are available.
“The Blackmer pump was the ideal solution for this ap- Matt Migliore is the director of content for Flow Control
plication because it offered solid technical characteristics, magazine and FlowControlNetwork.com. He can be reached
at 610.828.1711 or matt@grandviewmedia.com.
including low internal pressure losses, power efficiency, and
FLOWSTREAM Find related content @ flowcontrolnetwork.com…Search on:

OEM | Filtration | Matt Migliore | Pumping Systems | Refueling
45 YEARS
OF MAXIMIZING
UPTIME
Cat Pumps produces the longest-lasting, most durable
high-pressure triplex pumps on the market. For over
45 years, our products have been helping industry
get the job done. If you have an application running
between 100 and 10,000 psi with flows from 0.13 to
240 gpm, Cat Pumps has the right pump for you.
Download a copy of Cat Pumps “High-Pressure System

Design Guide” at www.catpumps.com/HPGuide.asp
Contact us at 763-780-5440 • catpumps.com
© 2014 Cat Pumps

OEM / SYSTEM INTEGRATOR Q&A | Best Practices
Q&A:
A Reasoned Approach
to TECHNOLOGY
PARTNERSHIPS
An industry insider offers insights on the keys to
success for OEMs and system integrators
David Nystrom is the general manager of TSi Power Products in Antigo, Wis.
Nystrom has more than eight years of experience in the power conversion indus-
try. He began his career in manufacturing and progressed to sales and market-
ing prior to leading TSi Power Products. TSi Power Products is a subsidiary of TSi
Power, (www.tsipower.com), a partner member of the Control System Integrators
David Nystrom Association (CSIA, www.controlsys.org).
Q: In your opinion, what are the most

important characteristics an OEM/
system integrator should look for in
a technology supplier?
A:
This question will naturally be defined
by the OEM’s own needs, which will
necessarily differ based on the orga-
nization.
If I must narrow it down to a single char-
acteristic relevant to all OEMs, I would say
accountability. The supplier must make every
good faith effort to deliver on its claims and
to stand by its product. Lead times should be
accurate, prices should not change without no-
tice, and service and warranty issues should be A TSi Power outdoor uninterruptible power supply serves a mission-
critical system at a nuclear power plant.
handled in a straightforward fashion.

Without accountability, the relationship between the OEM nology, how can the OEM properly evaluate prospective ven-
and technology supplier is inherently unstable. No matter how dors and their solutions? Only a shallow evaluation based on
good prices or technology specifications are today, there is no price, lead time, and marketing buzzwords will be possible.
guarantee this will remain so tomorrow. Worst of all, without Today this is much simpler than it once was. Reputable
accountability the OEM cannot count on long-term support industry associations and trade groups, whether professional
and may be stuck servicing complex technology. associations such as the IEEE or trade groups like the Control
System Integrators Association (CSIA, www.csia.org), make
a wealth of literature and training materials available online.
Q: If you could recommend one key first step for an

OEM/system integrator entering the technology
evaluation process, what would it be?
Much of this is free to boot.
A:
The first step must be for the OEM to thoroughly
educate itself on the technology it intends to
Q: How can OEMs / system integrators effectively
balance the price versus performance tradeoff
when considering potential technology partners?
acquire. Without thorough knowledge of the tech- What advice can you offer OEMs / system integrators to
Keep calm and meter on
Paddlewheel, Magmeter, Ultrasonic, Positive Displacement … how you

meter is up to you, but when do – pick the leader in how you meter with
Burkert Fluid Control Systems. Rugged and dependable, our low meters
are tough enough to stand up to rigorous and harsh environments without
sacriicing the accuracy and reliability you expect from Burkert.
For more info visit www.burkert-usa.com or call us at 800-325-1405.


OEM / SYSTEM INTEGRATOR Q&A | Best Practices
help them ensure they aren’t employing overly sophisti- accountability!

cated solutions or putting too much emphasis on the up- Missed deadlines, vague commitments, and changing
front cost (or cost savings) of an embedded technology? specifications or prices are all red flags. A good equipment
supplier communicates all of these things clearly, which is
A:
The tradeoff depends on what performance charac- essential for the OEM to be able to make plans. Is your equip-
teristics are demanded by the application. In an ment supplier consistently failing to deliver what it has prom-
application demanding very precise tolerances and ised? You need to find a new supplier.
“
control, a less sophisticat- One less obvious red flag
ed and less expensive solu- is when an equipment sup-
tion will ultimately cost
Without accountability, the plier is too quick to claim it
more because it will fail to relationship between the OEM has the perfect solution. If an
deliver adequate perfor- and technology supplier is inher- equipment supplier claims its
mance. But in a simpler technology meets all of your
ently unstable. No matter how
system requiring lower tol- requirements and then some,
erances and control, the good prices or technology it may be overpromising in
old saying, “better is the specifications are today, there an effort to secure your busi-
enemy of good enough,” is no guarantee this will remain ness. In the real world, few
applies. Not only would the existing technology solutions
user be paying more than
so tomorrow. Worst of all, with- are perfect, and even cus-
needed upfront, but more out accountability the OEM tom-developed technology in-
complex systems tend to cannot count on long-term sup- volves tradeoffs—not least of
have inherently higher fail- which is time and cost.
”
port and may be stuck servicing
ure rates—increasing oper- The best early diagnosis of
ating costs. complex technology. an equipment supplier can be
The question of capital made by seeing if it can ful-
costs versus operating costs is a common dilemma. In my ex- fill simple requirements, as promised in accordance with the
perience, too many OEMs are biased toward scrimping on the OEM’s needs. If the equipment supplier can’t solve simple
capital budget, only to suffer higher operating expenses down problems, it will fail to solve complex ones.
the road. Acquisitions cannot be handled solely by purchas-
ing managers. Field service managers, and other users of the
technology must be involved in the procurement process with
a strong focus on total cost of ownership. Unfortunately, it is
sometimes hard to make the case to spend more now to save
Q: What are some best practices OEMs / system
integrators can employ to effectively manage
partnerships with technology suppliers through-
more later. out the product development lifecycle?
A:
This comes down to two practices—measurement
Q: What are some red flags OEMs / system integra-

tors should keep an eye out for when interfacing
with equipment suppliers? How can an OEM /
and communication. An OEM needs to define what
performance acquired technology is to achieve and
verify this. Whether the technology performs or not, the infor-
system integrator make an early diagnosis on a technol- mation must be communicated to the equipment supplier in
ogy partnership that may be going the wrong way? a timely fashion. Otherwise, there is no way for an equipment
supplier to respond to changing conditions in the field.
A:
This brings us back to the first question, and the Additionally, it benefits an OEM to communicate details
matter of accountability. One strong red flag is if seemingly unrelated about the complete system’s perfor-
no single person at the equipment provider is in mance rather than only the performance of a particular ven-
charge of the relationship with the OEM. If no one is in dor’s technology. Good equipment suppliers are more familiar
charge, no one is responsible. That is the exact opposite of with their product than the OEM is, and they may be aware

of second order effects the OEM is not. Communicating this
information can result in unexpected cost savings and perfor-
mance improvements.
Q: What do you see as the key influencers in the
OEM / system integrator marketplace going for-
ward? How will the OEM / system integrator mar-
ketplace be different in the future than it is today?
Q: How has the OEM / system integrator marketplace

and/or technology landscape changed over the
past 10-20 years? Are there any external factors/
A:
The biggest influence I see is the rapid diffusion of
information and communications technology (ICT).
Whereas once the Internet primarily connected
trends in recent years that have had a significant impact on people and organizations, increasingly ICT now connects
how OEM / system integrator solutions are developed? machines. Much press has been made of this in the past
few years, for instance, General Electric’s “Internet of
A:
Old-fashioned “middleman” integrators and OEMs Things” initiative or the German government’s Industry 4.0
are disappearing. In the past, end-users relied on initiative.
integrators and OEMs not just to do field installa- Manufacturers are now incorporating Internet-connected
tions, but also to procure parts. This created some stable sensors into their products, allowing for precise measurement
environments in which integrators were able to profit on and control from remote locations. More advanced sensors
markups without adding a great deal of value. and controls allow for autonomous operation in some applica-
Increasingly, manufacturers and end-users are bypassing tions as well.
resellers and dealing with each other directly. Intermediary The OEMs and system integrators that survive and thrive
companies without expertise in systems integration, long- in the future will be those that master ICT. End-users often do
term maintenance, and other value-added services have seen not have the time or resources to setup and maintain com-
their position erode. plex computer networking technology, but they will demand
At the same time, more opportunities have been cre- the benefits provided by such networks. Intermediary compa-
ated for those integrators and OEMs with specific expertise. nies that master this valuable service will succeed. FC
Manufacturers have substantially increased the range and
capability of their products. This has led to new opportunities www.controlsys.org, www.tsipower.com
for intermediaries to offer long-term maintenance contracts,
turnkey setup deals, and even the complete takeover of end- Interview conducted by Matt Migliore, director of content
for Flow Control magazine and FlowControlNetwork.com.
user operations in some applications.
Connections for Fluid Applications

Stainless Steel • Nickel • Chrome • Non-Plated Brass
Auto-Couplings Non-Drip Fluid Couplings Multi Connection Plate Systems
For multiple connection systems with working pressure up to 4350 Couplings and nipples available in both valved and valveless CEJN custom built manifolds allow simultaneous connection and
PSI, lush-face, non-drip design. Multiple combinations of coupling/ combinations. Compatible with working pressures to 290 PSI disconnection of an unlimited number of lines for a variety of media.
nipple sizes and materials are easy to implement. Patented design and temperatures up to 600ºF. Aerodynamic valve design offers Multiple combinations of nipples/couplings sizes or materials available
allows connection/disconnection under full working pressure superior low capacity with minimal pressure drop. in stainless steel, brass, steel and anodized aluminum.
Customer.Service@cejnusa.com • 1-847-263-7200 • www.cejn.us

OEM / SYSTEM INTEGRATOR UP CLOSE | Custody Transfer
Ensuring the Efficient Measurement, Sam-

pling & Transfer of Liquid Hydrocarbons
The Lease Automation Custody Transfer (LACT) unit from Panhandle Meter,
supplied by Trigg Technologies, facilitates the transfer in ownership of liquid hydro-
carbons between a buyer and seller. The LACT’s main objective is to accurately mea-
sure, sample, and transfer hydrocarbons at both land-based and offshore facilities.
Trigg implemented a new ticketless system that has drastically reduced payment
turnaround time from 30 to 90 days down to 7 to 10 days. To improve efficiency
and output, Trigg Technologies partnered with Rockwell Automation and Microsoft
Corporation to upgrade to an information-enabled Midrange Architecture system,
leveraging an Azure cloud-based, remote asset-management solution.
FREE INFO: WRITE IN 110 | www.triggtechnologies.com
LACT control box

2 with HMI screen
Endress+Hauser
3 Coriolis flowmeter Block and
4 bleed valve
Backpressure
5 valve
Sampling
system
1
Key System Features:

✓Ticketless data entry, with ers to see measured variables,
diagnostics, and product quality
✓Proactive alarming capa-
automated hydrocarbon measure- bilities alert users to urgent
available on a dashboard.
✓Cloud and cloud-based

ment and billing enabled by the situations via text or email for
Rockwell Automation remote asset- immediate response.
✓Trending capabilities enable

management solution, eliminates
human error currently estimated to remote asset-management
range between 2 to 8 percent.
✓Access to real-time pro-

software provides mobile access users to view both historical and live
to data so users can access infor- data and follow performance in the
mation through a PC, tablet, or field over time, facilitating preventive
duction data allows stakehold- smartphone. and predictive action.

OEM / SYSTEM INTEGRATOR NEW PRODUCTS | Devices for OEMs
Automatic Industrial Timer Modbus Network Features

Designed to Meet OEM Flexible IP67 Display
Machinery Requirements
Automation Products
Automatic Timing & Controls’ Group, Inc.’s MND
(ATC) Model 175MU is a DIN rail- Modbus Network
mount multi-function automatic Display is designed
industrial timer, designed to meet with a flexible IP67
OEM machinery, equipment, and display and can be
related manufacturing require- operated in sniffer
ments. The ATC Model 175MU or master mode to
acts as a drop-in replacement for locally display volume,
most DIN rail-mount industrial level, distance, and/or pres-
timers, with a universal supply sure readings from any of the
voltage of 20-240 VAC (50/60 up to 10 sensors in a Modbus
Hz) and 12-240 VDC, 13 unique RTU network. Numerous user-
functions, and with 10 timing selectable standard or custom
ranges within a single unit. The units of measure are available.
timer comes standard in a 17.5 Readings are presented as a full five-digit
mm DIN rail-mount housing with display with large 0.4 in. characters for at-a-
a 5 amp SPDT relay output contact configuration and user- glance readability.
selectable time ranges, from 0.1 second up to three hours.
FREE INFO: WRITE IN 112 |
FREE INFO: WRITE IN 111 | www.marshbellofram.com www.apgsensors.com
High-Pressure Triplex Plunger Non-Drip Couplings Designed

Pump Designed for Long Life for Use in Low-Pressure Fluid
and High Efficiency and Vacuum Applications
Cat Pumps’ model 6810 CEJN’s non-

triplex plunger drip couplings
pump is are designed
designed for for broad use
continuous in low-pres-
duty applica- sure fluid and
tions requiring long- vacuum ap-
service life. V-packings plications.
and low-pressure seals are lubricated and cooled The coupling
to increase service life. Special concentric, high range is specially designed to meet performance
density, polished, solid ceramic plungers provide a and safety requirements of the fluids arena. CEJN
true wear surface that extend seal life. Block-style, developed the non-drip coupling range solely for
stainless steel manifolds are designed for strength fluid transfer applications and the product range
and corrosion resistance. A chrome-moly crankshaft is ideal for connecting all types of fluid lines, even
provides unmatched strength and surface hardness. those as diverse as beverage, electronic coolant,
The 6810 delivers a flow rate of 10 gpm (38 lpm) salt water, and oil transfer lines. The non-drip de-
and pressure to 10,000 psi (690 bar) at 600 RPM sign ensures virtually zero spillage and eliminates
making it ideal for high-pressure applications in gas, pollution and air inclusion during connection and
oil and mining applications. disconnection.
FREE INFO: WRITE IN 113 | www.catpumps.com FREE INFO: WRITE IN 114 | www.cejn.us

OEM / SYSTEM INTEGRATOR NEW PRODUCTS | Devices for OEMs
Two Series of Proportional Silencer Series of Gear Pumps

Control Valves Designed for OEM Applications
Clippard offers two Diener Precision Pumps’

series of proportion- Silencer Series of gear
al control valves pumps are designed for
designed OEM applications. The
to offer pumps feature pulseless
low hyster- flow (even at high pressure)
esis, low resistance to chemically
power aggressive fluids, durability,
con- ease of cleaning, and quiet
sumption, operation. The simple construction of the Silencer Series is
and to designed to ensure long life and make them easy to clean.
be easily Wetted materials are chosen to withstand a wide range of
adapted to control circuits. The compact aggressive chemicals. The enhanced gears and shaft bear-
EVP Series offers extremely high cycle life, ings have been optimized to ensure a long, trouble-free life
fast response, linear flow gain, and flows to and very low power consumption. The pumps are suited for
22 SLPM. For higher flow applications, the aggressive applications requiring high pressure at low flow.
new stepper-controlled proportional needle The manifold mounting simplifies the plumbing and reduces
valve provides up to 300 SLPM, millions of the installed cost in a system. A magnetic coupling ensures
cycles, and a very flexible design. the pump won’t leak. Pumps support flowrates up to 1,500
ml/min.
FREE INFO: WRITE IN 115 | FREE INFO: WRITE IN 116 |

www.clippard.com www.dienerprecisionpumps.com
Wireless Temperature/ Universal Transmitter Designed

Humidity Data Logger Features for Continuous Measurement of
User-Programmable Alarm Multiple Parameters
Dwyer Instruments’ Series WRDL The Electro-

Wireless Temperature/Humidity Data Chemical
Logger is a good fit for applications Devices Model
that require real-time monitoring and/ T80 Universal
or are in hard-to-reach locations. The Transmitter is a
data logger is designed to transmit up single chan-
to 500 feet indoors and up to 2,000 nel transmitter
feet outdoors. The distance can be designed for
increased by using additional receivers. the continuous
Wireless data is transmitted on a 2.4 measurement of multiple parameters in a gen-
GHz frequency giving it the ability to be eral-purpose industrial environment: pH, ORP,
used anywhere in the world. A network pION, dissolved oxygen, turbidity, conductivity, or
of data loggers can be separated into a resistivity. The T80 features a digital transmitter
smaller subnet, and these subnets can protocol to help simplify process measurement
all be controlled by a single PC. The Series WTDL data and to reduce maintenance costs for seven
loggers also feature a user programmable alarm. common industrial plant parameters.
FREE INFO: WRITE IN 117 | www.dwyer-inst.com FREE INFO: WRITE IN 118 | www.ecdi.com

Modules Provide OEMs with Fittings for
Communication Protocols Thermoplastic Hose
GE Intelligent Parker Hannifin’s global connect 56 Series

Platforms’ PACSys- Fittings for thermoplastic hose is designed to
tems RX3i modules provide complexity reduction for customers,
are designed to fewer parts to stock, and simplified crimping.
provide infrastruc- In addition, these new fittings are
ture OEMs and smaller, which should allow for
systems integrators tighter routings and
with communica- create space and
tion protocols as weight savings of
“in rack” solutions. up to 20 percent.
The PACSystems family of automation controllers, The new 56 Series
standardized on the PROFINET industrial network, Fittings is capable
provides an extremely high performance, reliable, of consolidating
yet simple to configure and install distributed I/O three series into
network. The Ethernet modules align with a growing one.
industry trend regarding the adoption of Ethernet-
based communications.
FREE INFO: WRITE IN 119 | www.ge.com FREE INFO: WRITE IN 120 | www.parker.com
Smart Pressure Transmitter Lead-Free Pressure

Includes Multiple Gauges, Thermometers
Communications Capabilities & Accessories
SOR, Inc.’s new 815PT Smart Pressure Trans- Winters Instruments’ new line of lead-free
mitter is a stick form-factor smart pressure trans- pressure gauges, thermometers and accessories
mitter that is built to be compact, has been manufactured to comply with the 2014
rugged, and explosion proof rated. Safe Drinking Water Act. The act, which took ef-
The 815PT has circuitry protected fect January 4th, 2014, limits the amount of lead
by a 316SS housing with 316SST content of
and 17-4SST wetted parts and has all products
hermetically sealed flying leads. It installed
is designed to produce outputs like in potable/
4-20mA and 1-5VDC, and it includes drinking wa-
multiple communications capabilities ter systems.
(HART, Modbus RTU). The 815PT is Winters
designed to give oil & gas field op- Instruments
erators, pipeline operators, and plant is a global
operators proper control and monitoring capability manufac-
to protect equipment, people, and the environ- turer of
ment. pressure and
temperature instrumentation, with distribution in
over 80 countries.
FREE INFO: WRITE IN 121 | www.sorinc.com FREE INFO: WRITE IN 122 | www.winters.com

OEM / SYSTEM INTEGRATOR ADVERTISER/PRODUCT 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
Advertiser Index Page RS# Advertiser Index Page RS# Product Index Page RS#
Adalet SS-BC 28 Sika USA Inc SS-3 23 Dwyer Instruments SS-12 117
Product Index Page RS#

Burkert Fluid Control SS-7 26 Electro-Chemical Devices SS-12 118
Systems
Automatic Timing & Controls SS-11 111
Cat Pumps SS-5 25 GE SS-13 119
Automation Products Group SS-11 112
CEJN Industrial SS-9 27 Parker Hannifin SS-13 120

Cat Pumps SS-11 113
Clippard Instrument SS-4 24 SOR Inc SS-13 121

Laboratory CEJN Industrial SS-11 114
Flow Research Inc SS-1 29 Clippard Instrument Trigg Technologies SS-10 110
SS-12 115
Laboratory
Harwil Corporation SS-3 22 Diener Precision Pumps SS-12 116 Winters Instruments SS-13 122
IN NO
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• In-stock and ready for immediate shipment
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OWN YOUR ENVIRONMENT
www.adalet.com 216.267.9000

seal can rub against the inside of the seal chamber. This will Once your pumps are humming happily along and your
cause the bearings to wear faster and unevenly. maintenance department has more free time and more mon-
This is the sort of damage that will put your pump in the ey in the budget, you’ll be able to breathe easy. Your bearing
maintenance shop rather quickly. and seal vendors may start to worry as you stop ordering so
Notice that while this scenario looks similar on the per- many parts. They’ll think you’re buying from somebody else.
formance curve to inadequate suction pressure, it is in fact At the end of the day, you will find a big ROI as your pumps
totally different. Your pump operator must be able to interpret work without failure and your processes are uninterrupted. FC
the pressure gauges effectively to determine what to do next.
The solution is simply to increase the downstream resis- Kelvin Findlay is an industry analyst and market-
tance. Your operator can restrict a discharge valve, increase ing manager at Automation Products Group, Inc. He
the pressure in a downstream tank, or increase the elevation is deeply involved in APG’s pressure measurement
differential by filling a downstream tank. product line for the Oil & Gas, Water & Wastewater,
Your discharge pressure will increase as you increase re- and Chemical industries. His passion for understand-
sistance downstream. This will pull your pump to the left on ing how and why sensors are used in the field drives
the performance curve—back to its BEP. As your pump comes his research and APG’s product development. Mr.
back to BEP, the vibrations and cavitation will disappear and Findlay can be reached at 888 525-7300, ext. 1054,
component failure will be avoided. or kelvinf@apgsensors.com.
What Happens When My Pump Produces www.apgsensors.com

Too Much Differential Head?
This means you have too much downstream resistance hold-
ing energy inside your pump. The excessive differential head FLOWSTREAM
drags your pump performance to the left of BEP. Find related content @
In this scenario, your pump will over-heat and vibrate. This flowcontrolnetwork.com…Search on:
also causes shaft deflection, but due to an increase of pres-
Best Efficiency Point | Maintenance | Pressure
sure instead of a loss. The impeller and shaft assembly will LarryBachus-datescartoon:Layout 1 11/6/12 3:56 PM Page 1
Gauge | Pump Curve | Reliability
deflect once again, but in the opposite direction, causing rub-
bing, wear, and premature failure.
Do You
Your pump will also start to cavitate as the temperature
and pressure combine to create imploding vapor bubbles.
The best way to fix this is to look for the excessive down-
stream resistance. Perhaps you have a clogged filter, a closed
valve, or build-up inside the pipes. If you’re filling a tank, per- Know & Understand
Your Pumps?
haps the tank has become too full. Maybe the pressure is too
high in a downstream tank or reactor vessel. Whatever the
problem, your operator needs to either relieve the resistance,
or shut off your pump. Larry Bachus ("The Pump Guy") is the
With a little bit of the right training, a good pump opera- co-author of Everything You Need to
tor can resolve these issues and extend the MTBF on your Know About Pumps, one of the best
pumps. All you need to provide are two pressure gauges for selling technical books on pump systems in
each pump. the world. This book is written exclusively for
people who must maintain pumps. Whereas
other pump books are written from a design
Take A Deep Breath point of view, this book is written with
At the end of the day, pumps are fairly simple. But they must maintenance in mind. While most technical
be operated properly—at or near BEP—in order to do the books sit on a reference shelf gathering dust,
job right. You must think of pump control as more than just this book gathers dirt smudges. Its pages get
turning them on and off. Install digital pressure gauges on creased and folded when mashed by the lid
both the suction and discharge nozzles of your pumps. Keep of a photocopy machine. It gets sneezed on
enough energy coming into your pumps, and make sure the and splashed with snot on cold mornings. It gets soaked with leaking oil, grease,
and coffee. Basically, it gets used ... because it's tremendously useful. The
differential head is kept within the safe zone. straightforward guidance it provides will help you ensure the efficiency and
There is an answer to high maintenance pumps. Pull out lifespan of your pumping systems.
your pump curves and use your pressure gauges to interpret
them. Involve the maintenance techs, the instrumentation To order your copy of Everything You Need to Know About Pumps,
techs, the process engineer, the reliability engineer, and even
call (615) 361-7295 or order online at
the number crunchers in management. Working together as a
team will make it a lot easier. www.bachusinc.com/books.html
FLOW UPDATE | Electromagnetic Flow Measurement
The Moneymaker
Why are electromagnetic flowmeters so popular? By Jesse Yoder, Ph.D.
M agnetic flowmeters generate more revenues worldwide current. This makes them better able to
than any other type of flowmeter, according to the lat- handle high noise applications, such as
slurries and dirty liquids than standard
est research compiled by Flow Research, Inc. This places DC meters. These high-strength me-
magnetic flowmeters ahead of some powerhouse flow ters are growing rapidly in popularity. In
measurement technologies, such as Coriolis, positive dis- 2008, they accounted for 5 percent of
placement, turbine, and differential pressure (DP). And magnetic flowmeter revenues. By 2013,
this percentage had more than doubled.
while the story is somewhat different in terms of units, with
differential-pressure and variable-area flowmeters having a New Product Developments
larger installed base than magnetic flowmeters, the higher Keep this Market Fresh
average selling price of magnetic devices has enabled the While the magnetic flowmeter market
is a mature and stable one, there are
technology to entrench itself as the biggest moneymaker in some new product developments in
the flow measurement category. the magmeter market, and these new
developments figure to help generate
Why Magnetic Flowmeters? As a result, AC magmeters needed to continued growth. One recent develop-
Most flowmeters do their best work in be calibrated regularly against an onsite ment is the advent of two-wire magnetic
clean liquids or gases. This is true, for hydraulic zero to maintain their accuracy. flowmeters instead of four-wire meters,
example, of turbine, Coriolis, transit-time Direct current (DC) magmeters were which have a dedicated power supply.
ultrasonic, and vortex meters. Magnetic developed to solve the problems associ- Two-wire meters use the power avail-
flowmeters, however, thrive in dirty liquid ated with the noise associated with AC able from the loop power supply. This
applications. As such, magnetic flowmeters. The DC meters were based on reduces wiring costs and can result in
meters are widely employed to measure pulsed direct current. When the current lower installation costs, which is mak-
the flow of conductive liquids and slur- is turned on, a voltage is generated in ing two-wire meters a popular choice of
ries, including pulp and paper slurries the magnetic flowmeter, showing the ve- end-users. While two-wire meters still
and black liquor. Their main limitation is locity of a flowing liquid. When the cur- represent only a small percentage of the
that they cannot measure hydrocarbons rent is turned off, any remaining voltage total magnetic flowmeters sold, their use
(which are nonconductive). is assumed to be the product of noise. grew significantly from 2008 to 2013.
Magmeters, as they are often called, The DC meter computes flow velocity by Another important development
are highly accurate and do not create subtracting this extra remaining voltage. is the growth in battery-operated and
pressure drop. Their initial purchase While DC pulsed technology was first wireless magnetic flowmeters. Battery-
cost is medium to high, depending on introduced in 1974, it became popular in operated meters make it possible to
size. While their price is generally higher the 1980s, and its popularity has grown install magmeters in hard-to-reach
than DP flowmeters, most are priced since then. In 2013, more than 95 percent places, and wireless meters can trans-
lower than equivalent Coriolis flowme- of magnetic flowmeter revenues were from mit a receivable signal where the use of
ters, making magmeters a nice choice meters using some type of DC technology. wires is impractical. Both of these seg-
for end-users who are aiming to strike a Pulsed DC technology does have the draw- ments represent fast-growing areas of
balance on price vs. performance. back, however, of lower signal strength the magnetic flowmeter market.
compared to AC meters. This gives AC Another area where magnetic flow-
AC vs. DC Magnetic meters an advantage for measurement of meters distinguish themselves is in their
Flowmeters some dirty liquids and slurries. liners. Liners enable the meters to mea-
When magnetic flowmeters were first To compensate for low signal sure both very dirty and very clean liq-
introduced, many had coils powered strength, some DC magnetic flowme- uids. The two most popular ones are PFA
by continuous alternating current (AC). ter suppliers developed “high-strength” (perfluoroalkoxy) and PTFE (polytetraflu-
These devices were subject to noise DC meters, which use the pulsed on- oroethylene). Hard rubber is widely used
that interfered with the meter reading. off technology of DC with a higher coil for water and wastewater applications.

Total Shipments of Magnetic Flowmeters southern China to the Yellow River Basin in arid northern China.
Worldwide (Millions of Dollars) Another massive water project in China is the Three Gorges Dam.
2500.0 There are a significant number of magnetic flowmeter suppli-
ers in China. Some of them are associated with Western com-
2000.0
panies, such as ABB, KROHNE, and Endress+Hauser, others
appear to be operating independently. Unfortunately, precise
1500.0
reporting from the new manufacturers in China remains an ob-
1000.0 stacle to a complete understanding of their contributions to pro-
duction volumes in this region. It is safe to say that the Chinese
500.0 market is a significant portion of the world market, and that this
is the fastest growing region for magnetic flowmeters. FC
0.0
2013 2014 2015 2016 2017 2018
Jesse Yoder, Ph.D., is president of
Source: Flow Research, Inc. Flow Research Inc. in Wakefield, Mass.,
a company he founded in 1998. He has
25 years of experience as an analyst and
The China Wild Card writer in process control. Dr. Yoder can be
The magnetic flowmeter market has grown substantially in China
reached at jesse@flowresearch.com.
and in the Asia-Pacific region in the past five years. China is
For more on Flow Research’s work in the
engaged in some very large water projects that are designed to
area of magnetic flowmeters, visit www.
bring water to low-rainfall areas. One example is the South-North Jesse Yoder flowmags.com.
Water Transfer Project, which is being built at a cost of $62
billion. Its purpose is to bring water from the Yangtze River in www.flowresearch.com

Flow Measurement | Jesse Yoder | Magnetic Flowmeters
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TECHNOLOGY SPOTLIGHT | Dispensing Systems
Concerning Fluid
Handling Safety
10 reasons to consider closed system liquid
dispensing for bulk shipping containers By Thomas A. Braun
A t any given time, there are millions of liquid-filled drums A third liquid-dispensing approach is
the closed or sealed system, and this is
and IBC totes in circulation around the world, transport- a significantly safer approach than ei-
ing everything from edible oils and flavorings to detergents ther the open or semi-closed methods.
and solvents or other hazardous media. These containers Closed systems rely on a pump to draw
provide industries an efficient way to deliver bulk liquid ingre- the media from the container and de-
liver it to the end process.
dients and products from the producers/manufacturers and Closed systems include three main
blenders who package them to the end users, who, in turn, components:
need to transfer the liquids into smaller containers or into Dip-tube assembly: This as-
equipment for end-use processes. sembly usually includes a drum insert
with a threaded plug that replaces the
Historically, the simplest transfer the work space. In addition, the semi- standard bung plug and a hollow down
method has been through an open dis- closed approach requires workers to in- tube or straw that extends to the bot-
pensing system by simply pouring the sert and remove a dip tube each time a tom of the container. The dip tube is
liquid out of the original shipping con- new drum is emptied—a process that pre-installed by the drum manufacturer
tainer into a bucket using a spigot. This still exposes them to drips, leaks, and or the packager of the contents at the
method, however, is typically messy and fumes during the transfer. time of filling. Alternately, the end-user
risks splashes and spills that may choose to install the dip
expose workers and the envi- tube in a safe area prior to
ronment to potential hazards delivering the container to the
from the liquid media, as well end process location.
as the fumes they generate. Dispense head or
Another common method coupler: This is a connector
used in many industries em- that can be easily affixed to
ploys a semi-closed dispens- the container to facilitate dis-
ing system where a sting- pensing of the media at the
er-type dip tube draws the end user’s site. The coupler
contents out of a vertically will be connected to a pump
oriented container using an using hose or tubing of some
attachable hand or electric/ sort that feeds the end-user’s
air-driven screw-type transfer process.
pump. Pump: Virtually any
While this approach is a type of pump (centrifugal,
step in the right direction, diaphragm, gear, vane, peri-
the semi-closed dispensing staltic, metering, proportion-
system is typically not sealed ing, etc.) can be used with a
and allows potentially danger- Figure 1. Fully closed dispensing systems rely on a pump closed system since a properly
ous fumes from the chemical to draw the media from the container and deliver it to the designed system will allow for
end process without worker exposure.
to pollute the atmosphere in connection to any pump inlet.

contact with chemicals. contamination. The semiconductor and
Because a closed system means the life sciences industries were among the
dip tube is pre-installed in the drum, first to implement completely closed
there is limited opportunity for contact systems. In these industries’ highly
between the container contents and sensitive manufacturing processes, the
the worker or the environment. As a fur- presence of even the smallest amount
ther protection, the dip-tube assembly of dust or foreign material can prove
can be specified with various styles of extremely costly. A closed system con-
shipping plugs to safely deal with inter- trols chemical purity from the point-of-
nal pressure created in the container origin through contents transferred and
resulting from either high vapor pres- all the way to the point-of-use.
Maximize Materials use

3 for Cost-Efficiency
A well-designed closed dispensing sys-
tem will also enable complete (99-plus
percent) emptying of a drum or IBC
tote, allowing for the most efficient
use of the materials for which the end
user has paid. This is especially impor-
tant when drum contents are costly
or if contents are hazardous, which
makes disposal difficult and/or costly.
Two methods are typically employed to
achieve this near-100 percent dispens-
Figure 3. Closed dispensing systems
ensure product purity by eliminating ing of contents:
dust or air contamination during the 1. A flexible dip
Figure 2. A closed dispensing sys- transfer process. tube, made slightly
tem includes a coupler (outlet, vent
port and locking ring), optional key longer than the
system to prevent misconnections, sure media or from changes in altitude drum height, will
and a drum insert and dip tube that or temperature that are different from bend and work
are installed in the drum prior to those present during filling. its way into
shipping. the outer
Maintain Purity of edge
Virtually any industry can benefit 2 Contents and Prevent
Figure 5. An accordion
from closed system dispensing of both Degradation bellows can also be used
hazardous and nonhazardous liquids Many industries and applications to make sure the dip tube
because there are multiple advantages require chemicals to be transported is in constant contact with
for manufacturers, shippers, packagers, and dispensed in a closed man- the bottom of the drum.
and end-users alike. Below are 10 rea- ner to prevent any possibility of
sons you may want to adopt or specify in the bottom of a drum during instal-
closed system dispensing for your bulk lation (Figure 4). Then, when the drum
liquid containers. is almost empty, a simple shim can be
inserted under the opposite side of the
Ensure Worker Safety drum to maximize emptying.
1 Closed-dispensing systems are
safer for workers because they elimi- 2. An accordion-type bellows device
nate exposure to hazardous liquids is affixed to the bottom of the dip tube
during storage, transfer and disposal. in order to maintain contact between
OSHA, along with other health and the bottom of the drum and the dip tube
safety organizations, is taking aggres- (Figure 5).
sive steps to minimize the chances of Both methods are effective in maxi-
chemical exposure for personnel and mizing emptying efficiency, reducing
the work environment. These increased Figure 4. The design of the dip tube waste, and minimizing the costs asso-
safety concerns are driving the trend is important so that it ensures the ciated with disposal. However, the ac-
complete emptying of the drum.
toward systems that prevent worker cordion bellows costs more because it

TECHNOLOGY SPOTLIGHT | Dispensing Systems
requires: an additional component (the

bellows); a much larger/stiffer dip tube Key Features of a Closed Dispensing System
in order to compress the accordion bel-
lows; and additional labor to assemble Ideally the coupler between the drum “blanket” gas such as nitrogen, car-
the bellows element to the dip tube. head and the end user’s tubing will bon dioxide or argon to protect oxy-
incorporate four main features: gen-sensitive media such as edible
Prevent Possible 1 An internal shutoff valve so that oils or high-purity chemicals used in
4 Misconnections when it is disconnected from the con- the microelectronic, solar and phar-
Optional features available on some tainer (either during change-out or stor- maceutical production industries.
closed dispensing systems help pre- age)the media will not drip and spill. 4 A simple and robust means
vent misconnections. Options include 2 A liquid outlet port that fea- to connect the coupler to the drum
color coding, physical keying, and use tures a variety of “fitting” options to insert that can be connected and dis-
of radio frequency identification (RFID) facilitate easy connection to system connected quickly while maintaining
technology or all three. Colored caps tubing. a leak-free interface. A keying system
can be placed on the coupler and 3 A separate, external venting provides the end user a visual (color
installed in the dip-tube assembly to port that allows make-up air into the coding) and/or mechanical means to
make it easy to match the coupler with container as liquid is removed but prevent accidental misconnects of in-
the right drum or IBC tote. In applica- can also be used to connect an inert compatible media.
tions using multiple drums containing
different products, color coding can pensing systems’ ability to remove up Continuous reduction of absolute
minimize the potential for misconnec- to 99.9 percent of the contents of a waste, energy, and water use
tions that could damage processes or drum, any additional costs associated Intentional design of products to
lead to costly contamination. with hazardous waste disposal may be be reusable, recyclable, or made
avoided or reduced. from renewable materials
Reduce Cleanup Costs Delivery of safer solutions that
5 By eliminating spills at the point- Support Sustainability meet the needs of customers and
of-use, closed dispensing systems also 7 Initiatives society.
eliminate costly and sometimes danger- Many companies today have made for-
ous cleanups. Not only can a closed mal commitments to environmental and Selecting and Installing
system prevent direct costs associated social responsibility; and using closed Closed System Dispensing
with cleanups, but it prevents produc- system chemical dispensing technology The decision to use closed system dis-
tivity losses by eliminating the need can contribute to these goals by helping pensing can be made by the drum or IBC
to divert personnel from more impor- organizations achieve: tote manufacturer, the chemical manu-
tant activities related to production. Zero occupational illnesses facturer, or even the end-user. For drum
Moreover, because the drum and dip- Zero discharges into the environ- and IBC tote manufacturers, low-cost
tube assembly can usually be recycled ment dip-tube assemblies can be pre-installed
as a unit, no labor or water resources Zero reportable incidents of any in empty containers prior to shipping
are required for drum cleaning and kind them to a customer; or a chemical
there is no contribution to the water Continuous improvement in en- packager can install them in containers
waste stream. ergy and water use efficiencies filled with liquids prior to shipping con-
tainers to a customer. Even
Reduce end-users with the facilities
6 Disposal Costs to safely handle materials
Polyethylene drums or IBC may choose to install the
totes featuring pre-installed dip tubes on-site just prior to
polyethylene dip-tube use. No matter at what stage
assemblies create a com- an integrated closed dispens-
plete package that can be ing system is implemented,
filled and emptied safely the ideal system will be one
and completely, and recy- that protects people and the
cled as a unit. Once a drum environment from chemical
is emptied and the shipping exposure, is easy to use, and
plug is inserted in the dip- improves profitability for all
tube assembly, the package parties—drum manufacturer,
is ready to safely ship to a chemical packager, and end-
Figure 6. Application of closed dispensing system
recycler. With closed dis- users alike.

Ship with Un/Dot HDPE containers, the cost savings and and non-hazardous industries. Closed
8 Approval return on investment of closed system dispensing systems that utilize a pre-
When a Jerrican, drum, or IBC tote is dispensing can be realized very quickly.installed dip-tube assembly in a single-
used to transport hazardous materi- For other applications that require dip trip drum are inherently safer, and they
“
als (HAZMAT) as defined can also be rugged, reli-
by the Environmental able, and affordable. This
Protection Agency (EPA, Optional features available on some last attribute, affordability,
www.epa.gov), the pack- closed dispensing systems help pre- is often the key determi-
age (container plus clo- nant as to whether these
sures) must pass the DOT’s vent misconnections. Options include safe and convenient sys-
testing regimen as defined color coding, physical keying, and use tems are implemented
in CFR 178 to verify that widely or at all.
the contents will be secure of radio frequency identification While open and semi-
during transport. This holds (RFID) technology or all three. Colored open systems will con-
true when the closure is tinue to be employed,
a pre-installed dip tube. caps can be placed on the coupler and drum manufacturers can
Packagers can choose dip- installed in the dip-tube assembly to improve customer accep-
tube assemblies that meet tance of their products
”
these standards. make it easy to match the coupler by offering a low-cost
with the right drum or IBC tote. closed dispensing system
Meet with a pre-installed dip-
9 Cleanroom tube assembly. Likewise,
Application Needs tubes or couplers made of stainless steel packagers can enhance both safety and
Industries with strict cleanroom manu- or exotic polymers, the materials price the acceptance of their products by of-
facturing standards (such as the semi- will be significantly higher, but the other fering pre-installed dip tubes that mate
conductor, solar, and life sciences benefits of closed system dispensing with coupler types favored by the end-
industries) can benefit from closed might still outweigh the cost. users. Finally, end-users gain benefits
system dispensing because dip-tube from closed dispensing systems that
assembly and coupler components can A Closing Argument for include greater worker and environmen-
be assembled under cleanroom condi- Closed Dispensing Systems tal safety, improved container emptying
tions that adhere to specific application Today, chemical packagers and end- efficiency, reduced cleanup/disposal,
requirements. Plus, the resulting closed users—well aware of the liabilities they costs and contributions to sustainability
system dispensing unit helps guarantee face—are increasingly incorporating and a cleaner world. FC
content purity from the point-of-origin closed systems into their chemical man-
to the point-of-use. agement solutions, both in hazardous www.colder.com
Control Costs Thomas A. Braun is the business manager of chemical and packaging
10 While convenience and safety are products for Colder Products Company in St. Paul, Minn. With Colder for more
both important goals for liquid dispens- than 20 years, he currently oversees business development efforts, assesses
ing, affordability is also critical. That new market opportunities, and develops program initiatives, including technol-
is why the drum inserts and dip tubes ogy licensing, patent evaluations, and contract negotiations. He developed and
of DrumQuik are constructed almost co-patented the pressure balanced non-spill coupling design and DrumQuik
entirely from high-density polyethylene dispensing connector system for Colder, both of which have won several industry
(HDPE). HDPE is inexpensive and an awards. Prior to joining Colder, he served in design engineering and mechanical
FDA grade that is suitable for food pro- research and development management roles at Tectonics Research Inc. and
cessing. It combines ruggedness with Advanced Compressor Technologies. He helped develop an efficient heat pump
resistance to a very wide range of while at Advanced Compressor Technologies, and he also developed and pat-
industrial chemicals. And since most ented a natural gas direct-injection system for two-stroke internal combustion
Jerricans, drums, and IBC totes are also engines. He holds a bachelor’s degree in Mechanical Engineering from Gannon
made of HDPE, the whole assembly is University in Erie, Penn., has three patents, and is involved in various industry
easily recycled. For high-volume users of associations. Mr. Braun can be reached at tom.braun@colder.com.

Chemical Processing | Dispensing | Fluid Handling | Hazardous Materials | Safety

THE PUMP GUY | Pumping Systems
mailbag: Calculus Gymnastics

Are universities adequately preparing student
Larry Bachus engineers for jobs in fluid handling?
L ast month, I wrote about a to 4 p.m. on Monday, Wednesday,
Igor Stevanovic/Getty Images/ThinkStock

young reliability engineer at a and Friday. Although that was 40
petrochemical plant who is wor- years ago, the properties of water
ried he might be transferred, or remain the same.
fired (Flow Control, January, page The professor will dedicate one
36). The engineering VP told him or two classroom lectures (this
to stop chasing vibrations and means 1 hour, possibly 2 hours)
make the vibrations disappear. to pumps. What can the profes-
(To be perfectly honest, you can’t sor say about pumps in an hour
make vibrations disappear; vibra- to students who might never have
tions can only be minimized to seen a pump or worked in heavy
acceptable levels.) industry?
There is a problem. The reli- The professor talks about the
ability engineer doesn’t know how development of pumps through
to calm the vibrations because he history. The professor says the
doesn’t understand his pumps. pump adds energy to a liquid. The
Now balance this with another is- professor quantifies the energy
sue on the other side of the earth. as either head (feet) or pressure
An engineering supervisor at a (PSI) with the math to convert one
global consulting engineering firm into the other.
in Europe wrote to ask, “What’s The professor reviews the
wrong with high suction pipe ve- design parameters (volute and
locity leading to a pump, assum- impeller geometry, suction spe-
ing the NPSH is met?” You might cific speed, NPSH, Affinity Laws,
ask, “Shouldn’t an engineer (and power consumption) important
supervisor) with a company that to pumps. The professor explains
designs power plants know about the difference between a positive-
liquid properties, velocity, and flow of the university. The engineering student displacement pump and a centrifugal
water through pipes? sits in the Fluid Mechanics classroom pump because some practicing en-
One of these engineers is the reli- for three hours a week. gineers will have to select one or the
ability team leader in a petrochemical Both liquids and gases are fluids. other for an application at some point in
plant. The other engineer is a supervisor Half the course is dedicated to the study the future. The professor shows a typi-
in a design engineering firm. How did of gas (including air) properties and the cal pump curve that contrasts head and
these engineers rise to their positions? way a gas behaves. This is called aero- flow.
How can they be leaders to mechanics, dynamics. The other half of the course The bell rings. The pump lecture
technicians, operators, and other engi- is dedicated to liquid properties and the ends. English or History class begins in
neers who clamor for leadership? way a liquid behaves in motion. This is five minutes in another building.
Most universities around the globe called hydrodynamics. In the next Fluid Mechanics class,
will graduate a mechanical engineer or So, the 16-week course only con- the professor lectures on how and why
chemical engineer in four years. One of tains eight weeks of dedicated liquid be- a vortex might form in the process of
the courses in the four-year curriculum havior. This doesn’t mean eight weeks draining a tank. The pump lecture as-
is called Fluid Mechanics. Pumps and at eight hours per day. It means eight sumes its position on the back burner
fluid behavior are covered in this course. weeks at three hours per week. I took of the student’s mind and slowly fades
The typical Fluid Mechanics course Fluid Mechanics in the Spring Semester out of memory.
runs for 13 to 16 weeks, depending on of 1973. I went to class from 3 p.m. Most mechanical and process engi-

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THE PUMP GUY | Pumping Systems
neering students graduate with a one or 2-hour lecture on neer will liaise with a subcontractor for the internal plumbing
pumps in a course called Fluid Mechanics. And this, people, pumps and the firewater pumps you might see in a building.
is what most graduate mechanical engineers and process en- He will review some pipe layouts and might have to sign a
gineers know about their pumps. requisition or pump purchase order.
I asked engineering professors at three different universi- Maybe the engineer will take a position with the highway
ties (Tennessee State University, Lipscomb University, and the department and build bridges and tunnels. For bridges over
University of Dayton) the following question: lakes and rivers, the engineer will need to recall open-channel
“In the Mechanical Engineering (ME) curriculum at your hydraulics from FM to design and sink caissons in water for
university, how many courses of Fluid Mechanics (FM) are bridge supports and design against floods.
required to graduate in four years as a mechanical or chemi- However, that one or 2-hour pump lecture in the Fluid Me-
cal engineer?” chanics course is woefully inadequate if the engineer takes a
“
One professor said, position with a petroleum
“All MEs, CivilEs and refiner, municipal water
ChemEs have one re- Larry, I don’t think the biggest issue department, mining, pow-
quired FM course. Fluid er plant, chemical plant,
Mechanics at our univer- is with how many courses of this or paper mill.
sity is purely theoretical. name are required. Higher education The third professor said
Our MEs will also take a it best. “Higher Education
Thermal Fluid Systems has moved to theoretical BS that is has moved to theoreti-
Laboratory where they largely an exercise in calculus gym- cal BS… led by a faculty
observe and analyze with absolutely no indus-
common mechanical en- nastics led by a faculty with abso- trial expertise, or even the
gineering systems includ- lutely no industrial expertise, or even context of being around
ing pumps. mechanical things.”
Another Ph.D. of En- the context of being around mechani- Too many universities
gineering (different uni- cal things. Professors without this are graduating mechani-
versity) responded, “For cal engineers who can’t
”
MEs, we require one experience always do what they are build a skateboard and
course in FM and another best at, namely calculus theory. don’t know what happens
course in Thermodynam- inside the engine of a car.
ics. Pumps are covered in It’s a problem I observe in
the FM course. Advanced FM is a technical elective. Our CivilE many parts of the world.
students also take FM with a hydrology lab.” If there is any interest in converting vibrations into reli-
The third professor (different university) answered, “MEs able pumps, come to a Pump Guy Seminar this year. We’ll
take one semester of FM. ChemEs take a different FM than be in Lake Charles, La. and Portland, Ore this year. For more
MEs. ChemEs also take a course called Heat and Mass Trans- details, visit FlowControlNetwork.com/PumpGuy or call Matt
fer. Civil Engineering students take a different course called Migliore at 610 828-1711. FC
Hydraulics, which is mostly open-channel flow and a course
on Water Resource Engineering.” Regards,
The third professor added an unexpected comment: “Lar- The Pump Guy
ry, I don’t think the biggest issue is with how many courses
of this name are required. Higher education has moved to Larry Bachus, founder of pump services firm Bachus
theoretical BS that is largely an exercise in calculus gymnas- Company Inc., is a regular contributor to Flow Control
tics led by a faculty with absolutely no industrial expertise, or magazine. He is a pump consultant, lecturer, and inventor
even the context of being around mechanical things. Profes- based in Nashville, Tenn. Mr. Bachus is a retired member
sors without this experience always do what they are best at, of ASME and lectures in both English and Spanish. He can
namely calculus theory.” be reached at larry@bachusinc.com.
Some graduating engineers will take a position with a
company that manufactures a product like an automobile, www.bachusinc.com
or piece of furniture. These companies need mechanical and
process engineers too. The engineer’s work week will be con- FLOWSTREAM
sumed with welding and assembly robots, assembly lines,
and packaging. These engineers might never need the infor-
Find related content @
mation covered in Fluid Mechanics.
flowcontrolnetwork.com ... Search on:
Some graduating engineers will take positions in construc- Larry Bachus | Maintenance | Pump Guy | Pump
tion. If the company erects buildings and stadiums, the engi- Guy Seminar | Vibration | Reliability

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AUTOMATION FILE | Industrial Communications
Q&A: Meet Ted Masters

The new president of the HART Communication Foundation
discusses the future of HART and industrial
communications technology
Ted Masters is president and CEO of the HART Communication Foundation, an

international, not-for-profit organization that manages the HART Protocol standards
and provides worldwide support technologies that leverage the HART Protocol. Ted
has held leadership roles in the process industry for about 25 years, including
work in a variety of technical companies delivering product, software, and service
solutions to industrial markets. His career has been centered on gaining access
Ted Masters
to operational data and turning it into business intelligence, enabling value-based
decisions for end-users. This includes large and small instrumentation, systems and
controls companies, as well as a predictive analytic enterprise software company now a part of
GE Intelligent Platforms.
Q: You recently replaced long- Finally, I am excited about taking ever, only when I worked with Elcon did
time HART Communication the Foundation to the next technologi- I get to see the value a relationship with
Foundation President, Ron cal level and making HART even more HART can yield.
Helson. How do you feel about being relevant in the age of the “Internet of At Elcon I worked closely with the
Mr. Helson’s successor and the role Things.” This needs to be carefully exe- Foundation to develop products, part-
of building upon the work he did in cuted to preserve the fundamental prin- nered with other member companies,
establishing the HART Communication ciples our users count on and keeping and enjoyed tremendous growth by
Foundation as a leading provider of HART reliable and secure in the cyber sharing the solutions we developed
protocols for industrial communica- age. within the HART ecosystem.
tions?
A:
Ron has built the Foundation
around solid principals that will
last. He has also set the direc-
Q: What was your relationship
with the HART Communication
Foundation prior to taking
Q: What do you see as some of
the key accomplishments of
the HART Communication
tion to maximize value for the members over as president? Foundation since its inception in 1993?
and open markets to drive the sale of
A: A:
their products. It is functioning quite Although I had been in the Well, that’s difficult to put a
well, yet there is still plenty of opportu- instrumentation and control box around, yet it is encapsu-
nity to optimize the performance of the world most of my career, I lated in the fact that the HART
Foundation and its processes. only began working closely with the Protocol is the recognized global leader
Also, a tremendous upside can be Foundation when I became president of for process automation communication.
achieved in growing our global foot- Elcon, a small member company (now Over 20 years, the Foundation accom-
print both in geographical areas and part of Pepperl+Fuchs, www.pepperl- plished this by demonstrating how to
with many technologies that are in their fuchs.us) similar to many of our mem- enable value to end-users through the
infancy. We can leverage the ground- ber companies today. use of HART data. With nearly 300
work Ron has put in place to scale From my background in sales and members composed of the most innova-
the membership and grow adoption in marketing I have stomped around many tive technology companies in the world,
many markets. Our strategic planning plants and view the business from the we now have the critical mass to drive
will align with these goals and put the user’s perspective. I understand the member solutions into the marketplace
proper initiatives in place to enable fur- large control system, data acquisition, to connect and enable the HART data to
ther growth. and instrumentation companies; how- be utilized by any system imaginable.

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AUTOMATION FILE | Industrial Communications
Q: From your perspective, what

were some of the more chal-
lenging aspects of HART’s
ing a value proposition at the plant level
that is compelling for utilizing HART data
in real time. It’s all downhill from there.
A:
We have formed a study group
to investigate all the ways that
such a merger would provide
path to where it stands today? Many new ways to connect will drive additional value and make it easier for
member solutions and keep HART on our members and users. We have been
A:
I would have to say getting the cutting edge of digital communica- working hard at this task for months with
over the perception that HART tions. Growing wirelessly enables op- the goal of optimizing a proposed new
is an analog protocol that tions to cost-effectively bring in data Foundation to ensure it provides benefits
measures a 4-20mA current across a that would otherwise not be considered. to members of all types. As you may
wire. Digital communications run across We will grow in our ability to integrate imagine, there are many moving parts
many media, and it just so happens in with decision-support systems and soft- and so much work to be done to cover all
the case of HART that this media is the ware to leverage analytics and improve the bases before we deliver a well
thought out plan and benefits
to the members, who will
ultimately decide. Thus far
the results are very encour-
aging, and we are making
good progress toward a new
Foundation that benefits all.
Q: Looking ahead 10
years, how will
industrial commu-
nication be different than it
is today? What do you see
as the key accomplish-
ments going forward?
A:
I believe the data
delivered will be
smarter and have
Wired or wireless HART Communication protocols are designed to enable users to connect more inherent intelligence.
to the valuable information in their intelligent measurement and control devices, including We will take further steps to
real-time diagnostics, performance and status alerts, and device configuration data. system-wide interoperability,
standardizing both devices
most reliable, secure, and prevalent asset management. and various hosts. Many process auto-
form of communication in the process Delivering the HART data enterprise- mation technologies will work together to
industry. Now that the market recog- wide is the next step to maximizing its deliver ways to connect to this valuable
nizes that this is a digital protocol that use in all operations and management data.
can reliably bring the intelligence of functions of the modern plant today. Data will be more accessible enter-
their devices to connect with hosts, it This integration is also fueled by stan- prise-wide in the modern day plant and
opens up the value without being dis- dardization at the host level, which will available in the context needed to help
ruptive to their operations. be a key focus for the Foundation. people in various departments make
Finally, more can be done on a world- better decisions to optimize their opera-
wide basis to work cooperatively with tion. Plants will get much smarter and
Q: In the future, where do you other countries and standards and make integrated, but the people will still make
see the HART Communication it easier for users and members to gain the decisions of financial value that im-
Foundation going under your access to their data, and to register and pact their operation and livelihood—and
leadership? What are your goals for support HART devices and hosts. they will have far greater intelligence to
the organization over the next 5-10
years?
Q: It was recently announced make those decisions. FC
that the HART Communication
Foundation and the Fieldbus
www.hartcomm.org
A:
It all starts with the ultimate Foundation are discussing a possible Interview conducted by Matt Migliore,
goal of improving our end- merger. What can you tell us about director of content for Flow Control
magazine and FlowControlNetwork.com.
users’ operations and deliver- the status of the merger?

W ELC OME S
to the Technology Portal program.

GPImeters.com will be providing ongoing coverage of Turbine Flowmeters
as an exclusive sponsor of the Portal Program at FlowControlNetwork.com.
We encourage you to visit the following microsite for applications and

technology solutions related to Turbine flow measurement.
Turbine Flowmeters
flwctrl.com/TurbineMeters
For more information about Flow Control’s Technology/Application Portal program, please
contact Mike Christian at (908) 507-5472 or MikeC@GrandViewMedia.com.
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ADVERTISER/PRODUCT 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
Advertiser Page RS# Advertiser Page RS# Advertiser Page RS#
Ashcroft Inc 29 16 GF Piping Systems IFC 1 Pump Guy Seminar 31 NA
Assured Automation 4, 37 4, 200 International Biomass 13 9 Sage Metering 9 7

Conference
Bachus Company Inc 21 NA Interphex 7 6 Spitzer and Boyes LLC 12 8
Burkert Fluid Control Thermal Instrument

23 15 John C Ernst Company 16 12 16 11
Systems Company
CME Aerospace Control

Products 37, 40 201, 19 KROHNE Inc 1 2 Viega LLC IBC 20
203, PRODUCT INDEX Page RS#

Endress+Hauser BC 21 Kuriyama of America 37, 37
205
Ashcroft Inc 36 100
Flexim Americas Corp 15 10 Magnetrol International 3 3

Burkert Fluid Control
36 101
Systems
FMC Technologies 5 5 Omega Engineering Inc 17, 37 13, 204

Endress+Hauser 36 102
Flow Control Career Center 33 NA Parker – Porter Instrument 19 14 Omega Engineering 36 103
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THINK TANK | Analytical Systems
N T T I I N F O R M A T I C S C I R A S GLOSSARY OF TERMS:
G C E L U V S P E C T R O S C O P Y T T ANALYTICAL SYSTEMS
N F S A S I S Y L A N A R E T A W B A L
I L A B W A T E R A N A Y S I S E A T U
CHARACTERIZATION: Testing the processability of plas-
tics, pharmaceuticals and cosmetics, paints, coatings, and
B S R A C H A R A C T E R I Z A T I O N
materials from the chemicals and petrochemicals industries.
U P M U P C I T L A T S I R R E P P P I For pharmaceuticals, it can be used for drug development
T Y R T E M O R T C E P S S S A M M N P (hot melt extrusion) and continuous wet granulation.
C S B O T R A N R R S S Y S A P U U O R
FLOWMETERS: Variable-area flowmeters (rotameters) are
I C A M F L O W M E T E R M U P U P I H
used to measure the flowrate of liquids and gases in a vari-
T E V A C U U M P U O E S P C T A M T F ety of laboratory and industrial applications. These meters
L T O T A L Y C E P T R M I O R T U E E consist of a spherical float moving vertically in a glass flow
A A S I C C C N S E E U T P S O C U M T tube with a tapered inside diameter.
T M T O T R S T M T U L F A A P S C O I
S R P N L I A W I C A T A I T M A A T M
INFORMATICS: Laboratory Information Management
Systems (LIMS) and Chromatography Data Systems (CDS)
I O N C H R O M A T O G R A P H Y V U T are relied upon to manage data, resources, and workflow.
R F C A E L W V S A Z I N T O G I R A R
E N P R F U R I N F O R M A T I C I B F
ION CHROMATOGRAPHY: An instrumental technique for
separating and measuring substances that are dissolved in
P I R L L R R P A V Y C N T S A E E A T
water.
E I I F L E R C P P T C U S R W E R L R
R I T I P M G T P L H T C T M E R T E T LAB AUTOMATION: Flexible, modular drug discovery
platforms that can automate virtually any assay, method,
CHARACTERIZATION MASS SPECTROMETRY or protocol, including robotic platforms for microtiter plate
applications, instrument integration, and scheduling and
workflow software.
FLOWMETERS PERISTALTIC TUBING
LAB WATER ANALYSIS: Technology, such as electro-
INFORMATICS PERISTALTIC PUMP chemistry sensors and meters for pH, conductivity, dis-
solved oxygen, and various ion selective electrodes and
ION CHROMATOGRAPHY TEA colorimetric instruments and reagents.
MASS SPECTROMETRY: An analytical technique that

LAB AUTOMATION UV SPECTROSCOPY is used for determining the elemental composition of a
sample or molecule, as well as for elucidating the chemical
LAB WATER ANALYSIS VACUUM PUMP structures of molecules, such as peptides and other chemi-
cal compounds.
Solve This Word Search PERISTALTIC TUBING: Elastomeric tubing typically pro-
Win a $50 Best Buy Gift Card duced with tight tolerances and specially formulated mate-
rials to operate in a peristaltic pump.
One lucky entrant who has solved the puzzle correctly will win a $50 Best Buy
gift card. Best Buy is North America’s leading consumer electronics retailer. PERISTALTIC PUMP: These are rotating positive-dis-
You can use your gift card in the store or online at www.BestBuy.com.
placement pumps—where the rotor squeezes peristaltic
Fax solution to: (205) 408-3799 pump tubing against an occlusion bed.
If there are no completely correct entries, a winner will be selected
from among the entries with the most words found. TEA: (Trace Elemental Analysis) Range of advanced ana-
I would like to receive/continue Flow Control magazine: ____ Yes ____ No lytical instrumentation used to detect elements in trace
quantities down to below 1 part per trillion (ppt).
Signature: _____________________________________ Date: _________________
Name: ________________________________________________________________
UV SPECTROSCOPY: Used to quantify the amount of a
constituent in an unknown or finished liquid or solid.
Title: _________________________________________________________________
Company: _____________________________________________________________
VACUUM PUMP: Pumps that are specifically designed
to generate vacuum. A wide variety of vacuum pumps
Address/City/State/Zip: __________________________________________________ exists; diaphragm, rotary, scroll, turbomolecular, and pis-
______________________________________________________________________
ton style. They can either be “oil-less” or operate in an oil
bath—those that use an oil-bath typically generate high
Phone:________________________________________________________________ levels of vacuum. Oil-less design are cleaner and less
E-Mail:________________________________________________________________ likely to contaminate critical environments. Used for a wide
variety of applications for air sampling, gas handling, and
vacuum filtration.
November Winner: Randy Roth, Engineer
The terms and definitions for this word search were pro-
Cardinal IG, Tomah, WI vided by Thermo Fisher Scientific (www.thermofisher.com).

THINK TANK | Flow Measurement
By David W. Spitzer
quiz corner: What’s a Volumetric Flowmeter?
W hich of the following flowmeters mea-

sure the actual volume of fluid passing
through the flowmeter?
A. Coriolis mass
B. Magnetic
C. Orifice plate
D. Oscillating piston
E. Oval gear
F. Thermal
G. Turbine
H. Venturi
I. Vortex shedder
Commentary actual fluid volume should use volumetric units of measurement.

Positive-displacement flowmeters constantly entrap fluid This is usually the case for positive-displacement flowmeters. For
and measure the actual volume of the fluid. There are many example, my domestic water flowmeter measures in cubic feet.
positive-displacement flowmeter geometries available to However, there are some applications where other mea-
meet various application requirements. Applications can surement units are used. For example, some positive-dis-
vary from ubiquitous to highly specialized. Examples include placement flowmeters display in mass flow units when the
domestic water flowmeters and components in a two-phase fluid density is known and stable. FC
flow measurement system, respectively. Flowmeters that uti-
lize positive-displacement technology are the only flowmeters David W. Spitzer is a regular contributor to Flow
that measure the actual volume of the flowing fluid. Control magazine and a principal in Spitzer and Boyes, LLC
Coriolis mass, magnetic, orifice plate, thermal, turbine, offering engineering, seminars, strategic, marketing con-
Venturi, and vortex-shedding flowmeters are not positive-dis- sulting, distribution consulting and expert witness services
placement flowmeters. Oval gear and oscillating piston flow- for manufacturing and automation companies. Spitzer and
meters are positive-displacement flowmeters. Boyes is also the publisher of the Industrial Automation
The correct answers are Answers D and E. Insider. David can be reached at 845 623-1830.
Additional Complicating Factors www.spitzerandboyes.com

From an academic perspective, flowmeters that measure the
GAS FLOW ACCURACY

FLOWSTREAM
ASSURED
Find related content @
flowcontrolnetwork.com… Search on:
with Model 60B Flow Computer David W. Spitzer | Flow Measurement | Positive-Displace-
ment Flowmeter | Quiz Corner | Volumetric Flowmeter
November Solution: HVAC

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

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I L A N A I N S I O H A R G O I G I S S
L T R M R I U U L O O C B U S N D I P R
The originators of gas laminar flowmeters
/Div. of Aerospace Control Products, Inc.
A A L O U V O R E L L O R T N O C E R E
1314 West 76th Street, Davenport, IA 52806 • FAX: 563-391-9231 R E E C A P S M U N E L P E L I R N R R

E-mail address: info@cmeflow.com T H R U R R U T C I S I N Y H C T R S C
Write in 19 or Request Info Instantly at www.FlowControlNetwork.com

Introducing
Introducing Viega
new Viega
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ProPress®
Viega is the only manufacturer Zero Lead™
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Viega ball valves feature:

• Multiple conigurations,
P x P, P x FPT and
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• 316 stainless steel ball
• Choice of P x P valve
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• Available in sizes from

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Redefining Pump Control • What Is a Volumetric Flowmeter?

• Closed System Liquid Dispensing

FEBRUARY 2014 Vol. XX, No. 2

Are you looking for a truly universal flowmeter?

KROHNE – Process instrumentation is our world.

KROHNE, Inc. • 1-800-FLOWING • info@krohne.com • us.krohne.com

Write in 2 or Request Info Instantly at www.FlowControlNetwork.com/freeinfo

Redefining Pump Control

Considering the Popularity

Fluid Handling Safety

2 | February 2014 Flow Control Magazine

Better Signal-to-Noise Ratio Means

magnetrol.com • 1-800-624-8765 • eclipse.magnetrol.com

28 PUMP GUY departments

On the Cover: Background image by Ulla Rose/iStock/

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4 | February 2014 Flow Control Magazine

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The Business of Ethics G R A N D

Virginians. And while the investigation to determine EXECUTIVE DIRECTOR OF CONTENT

6 | February 2014 Flow Control Magazine

FRESH IDEAS & INSPIRING EDUCATION BY PDA (PARENTERAL DRUG ASSOCIATION)

TECHNOLOGY FLOOR TOURS SHOWCASING THE LATEST EQUIPMENT & INNOVATIONS

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March 18 – 20, 2014 Register today for

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As Technology Brings New Features

T echnology has undoubt-

8 | February 2014 Flow Control Magazine

The Bakken | Three Forks

International Fuel Ethanol

National Advanced Biofuels

www.flowcontrolnetwork.com February 2014 | 9

Texas Leads the Way as US Oil & Gas Projects Rise

the value of industrial projects sched-

Ghana’s Offshore Oil & Gas Sector Shows Promise

Business Monitor (www.busi- grow from around 110,000b/d

10 | February 2014 Flow Control Magazine

Developing Regions Drive Strong Growth for Water

2014 North American Industrial Project Start

best practices & standards

FCC Revises Rules Regulating Frequency Bands for

www.fcc.gov) has adopted rules geared specifically

www.flowcontrolnetwork.com February 2014 | 11

The Things You Don’t Know

David W. Spitzer is a regular contributor to Flow

14 | February 2014 Flow Control Magazine

Measuring Extremely Low Flowrates

Devices in all three categories can offer valid and use-

www.flowcontrolnetwork.com February 2014 | 15

Reducing Energy Usage

THERMAL INSTRUMENT COMPANY

16 | February 2014 Flow Control Magazine

Low Flow Velocity | Variable Frequency Drive

www.flowcontrolnetwork.com February 2014 | 17

R ather than learning how to optimize pump performance

18 | February 2014 Flow Control Magazine

www.flowcontrolnetwork.com February 2014 | 19

This can happen if your

20 | February 2014 Flow Control Magazine

SOLUTIONS for FLUID MOVEMENT,

Q&A: An industry insider offers