Flowcontrol201106 DL

Reections From a Pioneer of Flow Pump Guy Goes Sherlock Holmes Pipe Flow Problems Solved
JUNE 2011 Vol. XVII, No. 6 www.FlowControlNetwork.com
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COPYRIGHT 2011 OMEGA ENGINEERING, INC. ALL RIGHTS RESERVED
june 2011
Vol. XVII, No. 6
features
12
12 Mission Possible
analog-to-digital valve upgrades

Transitioning
from analog
to digital valve
positioners is a
move more and
more end-users
are effectively
taking on.
20 2011 Flow Control Innovation Awards

and the nominees are
34 Ge F. Fischer Tells It His Way
reflections from a pioneer of flow measurement
37 Flow Problems Solved
20
forum selections from pipeflowcalculations.com
2011 Innovation
columns
NOMINEE
4 VIEWPOINT keeping it simple

10 APPLICATIONS CORNER
part IV: vortex flowmeter postmortem
40 THE PUMP GUY
pump problem solved through observation & deduction
The 2011 Flow

Control Innovation
Awards nominees
highlight the years
most compelling
fluid handling technology advances.
34
departments
6 NEWS & NOTES the secret behind nists gas detector; fieldbus foun-
dation releases flow transducer block; cement plants to spend $2.6 bil.
on pollution controls; process automation market to rise through 2011
47 THINK TANK pressure regulators

48 QUIZ CORNER measuring fluid viscosity
plus
45 REFERENCE SHELF
46 ADVERTISER INDEX
46 PRODUCT INDEX
SUbSCRIPTION INFORMATION
Toll Free: 866.721.4807
Outside US: 847.763.1867
Mail: P.O. Box 2174
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On the Cover: The digital valve positioner shown on the cover is courtesy of GE Energy (ge-energy.com).
2 June 2011
Ge F. Fischer, founder
of the Instromet Group,
has had a long and
storied career in the
flow measurement
business, and he still
may have a trick or
two up his sleeve.
Flow Control (ISSN #1081-7107) is published 12 times a year by Grand View Media Group,
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A controlled circulation publication, Flow Control is distributed without charge to qualified
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industry. Contact the editor for details. Product/service information should be submitted in
accordance with guidelines available from the editor. Editorial closing date is two months prior
to the month of publication. Advertising close is the last working day of the month, two months
prior to the month of publication.
Flow Control
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viewpoint
Keeping It Simple
s i sit here on the morning of the u.s. Memorial

Day holiday, it occurs
to me that i am truly thankful to have the opportunity to
address you in this fashion.
after what has been a long
few years of economic uncertainty, there are some positive
reports starting to emerge
that signal a return to a more
stable business climate. For
example, a recent report by
the american Machine Tool
Distributors association and the association
for Manufacturing Technology showed
manufacturing consumption through March
is up 118.6 percent over the year prior. and
while there are major economic issues that
still need to be resolved such as looming
debt crises and unemployment in the united
states and Europe i can feel myself starting to breathe a little easier.
as thankful as i am to have been among
the lucky ones who emerged from this Great
recession with my professional life intact, i
also recognize the quest for survival is not
over it never is. if anything, the recent
troubles of the global economy have shown
us that we cannot afford to be complacent;
we must constantly look for ways to improve.
That said, in the complex and ever-changing
world in which we operate, it can be difficult
to navigate the road toward improvement.
My advice is to keep it simple.
in my opinion, our recent economic
struggles have a lot to do with making things
more complicated than they need to be.
For example, lets consider the mortgage
crisis here in the united states. a mortgage,
in its most basic sense, is generally a loan
designed to enable a person to purchase a
house. on the lenders side, success is determined by the complete repayment of that
loan with interest. on the borrowers side,
success is determined by the ability to purchase a home that meets the domestic need
at a rate of repayment that will be affordable
over the life of the loan. somewhere along
the line, the parties on both sides of this
equation lost their way and rationalized illadvised strategies that produced loans that,
4
June 2011
G r a n D
GV
V i E W
M E D i a
G r o u P
on the lenders side, were

unlikely to be repaid and, on
the borrowers side, were
unlikely to be affordable over
their term.
in a world where we are
all struggling to find new
ways to support our businesses, it is not uncommon
for folks to lose sight of their
core mission when tempted
by the promise of financial
benefit. ironically, this is, in
my opinion, the point at which
businesses are at the highest risk of financial
ruin. This is to say, when a business loses
sight of the product or service it is designed
to provide and begins to pursue monetary
gain without clearly considering how decisions along this line will affect the quality of
the product or service delivered, then it is
compromising its long-term viability.
Going forward, as i look for ways in which
i can be better at my job, ill keep this lesson learned in mind. My job, in its most
basic sense, is to provide relevant, informative, and interesting content to professionals
involved with uid handling applications. To
do my job better, each decision i make in my
professional life should be evaluated based
on whether or not it will positively, negatively,
or neutrally affect the content we provide.
in my opinion, if we were all to define our
jobs in their most basic sense and to evaluate the decisions we make based on how
they affect the quality of the jobs we do and
our organizations end product or service,
our businesses would be stronger and more
resilient. on the other hand, if we allow ourselves to be distracted by what some may
describe as the complexities of modern
business, we are entering into a risky area
where it is far easier to rationalize ill-advised
strategies that may be doomed to failure.
as we kick off the summer months and
hopefully continue along a path toward economic recovery worldwide, heres to keeping
it simple. FC
Matt Migliore, Editor-in-Chief
Matt@GrandViewMedia.com
PUBLISHER
John P. harris | (205) 408-3765
john@grandviewmedia.com
ASSocIAtE PUBLISHER
MiChaEL C. ChrisTian | (732) 200-5963
mikec@grandviewmedia.com
EdItoR-In-cHIEf
MaTT MiGLiorE | (610) 828-1711
matt@grandviewmedia.com
coPyEdItoR
sCoTT nEsMiTh
coLUmnIStS
Larry BaChus;
DaViD W. sPiTZEr; JEssE yoDEr
ARt dIREctoR
JuLiE FLynn
julie@grandviewmedia.com
mARkEtIng mAnAgER
Mary BETh TiMMErMan
SUBScRIPtIon REQUEStS:
owcontrol@halldata.com
foR REPRIntS, contAct:
owcontrol@grandviewmedia.com
Administrative team
gEnERAL mAnAgER
Barry LoVETTE
VIcE PRESIdEnt of oPERAtIonS
BrEnT KiZZirE
VIcE PRESIdEnt of mARkEtIng
hanK BroWn
dIREctoR of cIRcULAtIon & fULfILLmEnt
DELiCia PooLE
ASSocIAtE dIREctoR of cIRcULAtIon
BranDy PaTE
cIRcULAtIon mAnAgER,
ELEctRonIc PRodUctS
sTaCiE MurPhrEE
VIcE PRESIdEnt of fInAncE
BraD younGBLooD
EdItoRIAL AdVISoRy BoARd

Larry Bachus: Bachus Company inc.
Gary Cornell: Blacoh Fluid Control
Jeff Jennings: Equilibar LLC
Peter Kucmas: Elster instromet
Jim Lauria: amiad Filtration systems
James Matson: GE Measurement & Control
John Merrill, PE: EagleBurgmann industries
Jerry stevens: Endress+hauser u.s.
David W. spitzer, PE: spitzer and Boyes LLC
Tom Tschanz: Mcilvaine Company
John C. Tverberg: Metals and Materials
Consulting Engineers
Jesse yoder, Ph.D.: Flow research inc.
WINNER
WINNER
WINNER
WINNER
WINNER
Flow Control
If youve paid for automatic control valves,

none of your loops should have to be in manual mode.
There must be a better way.
Loops in manual mode due to poor-performing rotary valves require constant operator
attention. And they cost you process efciency. You can expect better control from the
new Fisher Control-Disk valve from Emerson. The Control-Disk valve has double the
control range of traditional buttery valves to allow control closer to the target set point,
regardless of process disturbances. You can keep your loop in automatic mode. With low
maintenance requirements and availability to ship in two weeks, its time to put a
Control-Disk valve in your loop. Visit www.Fisher.com/ControlDisk to watch an
animation video or download a brochure.
The Emerson logo is a trademark and service mark of Emerson Electric Co. 2011 Fisher Controls International LLC MV20-CD210
news & notes
The Secret Behind NISTs New Gas Detector
race gas detection, the ability to

detect a scant quantity of a particular
molecule a whiff of formaldehyde
or a hint of acetone in a vast sea of
others, underlies many important applications, from medical tests to air pollution
detectors to bomb sniffers. Now, a sensor recently developed* at the National
Institute of Standards and Technology
(NIST, nist.gov) that is hundreds of times
faster and more sensitive than other similar technologies may make such detectors
portable, economical and fast enough to
be used everywhere.
According to NIST investigators, the new
sensor overcomes many of the difficulties associated with trace gas detection, a
technique also used widely in industry to
measure contaminants and ensure quality in
manufacturing. A trace level of a particular
gas can indicate a problem exists

nearby, but many sensors are only
able to spot a specific type of gas,
and some only after a long time spent
analyzing a sample. The NIST sensor,
however, works quickly and efficiently.
A major hurdle the new technology overcomes is that it is now
possible to look at nearly all possible gas molecules instantly using
terahertz frequencies. Previously, it
was necessary to expose molecules
to a vast range of terahertz frequenGraph shows the NIST detectors linear increase in
cies slowly, one after another.
Because no technology existed that frequency as a function of time, sweeping from 550-561
could run through the entire frequen- Gigahertz in frequency over 100 nanoseconds.
Image courtesy of Plusquellic, NIST
cy band quickly and easily, the NIST
team had to teach their off-the-shelf
on its creation, which can plug into a power
equipment to chirp.
outlet and should be robust enough to surThe NIST team has applied for a patent
vive in a real-world working environment.
trendlines
Cement Plants to Spend $2.6 Bil. Per Year On Air Pollution Controls
Mil $/year
Avg. Annual Air Filtration Equip. Expenditures in

New hazardous air-pollution rules
Avg. Annual Air Filtration Equip. ExpenCement
Industry, Worldwide 2011-2014 (MILLION $)
ditures in Cement Industry, Worldwide
for U.S. cement plants will boost
2011-2014 (MILLION $)
$900
the market for air pollution control
Thermal
$800
Oxidizer $150
in the United States, as will infra$700
$600
structure growth in the develop$500
ing world, according to market
Scrubber
$400
$350
analysis by McIlvaine Company
$300
Fabric Filter
SNCR
$100
(mcilvainecom pany.com).
$200
$1,800
$100
Despite the boost from the new
SCR $120
$0
U.S. rules, McIlvaine says the U.S.
Fabric Filter Electrostatic
SCR
SNCR
Scrubber
Thermal
Electrostatic
Precipitator
Oxidizer
market will be smaller than the
Precipitator $105
Air Filtration Equipment
Chinese market through 2014.
US China ROW
Source: McIlvaine Company
The United States will lead in purcant market for activated carbon in the
of whether they are in a developed or a
chases of scrubbers and thermal
U.S. The EPA expects most U.S. plants to
developing
country.
oxidizers, but fabric filters will be the larginstall activated carbon injection systems
SO2
is
of
increasing
concern
in
the
est equipment category.
to remove mercury. This could result in
United
States
and
Europe,
and,
as
a
result,
The cement plants around the world
boosting total activated carbon sales in the
McIlvaine
says
wet
limestone
scrubbers
are increasingly utilizing fabric filters for
United States by 5 percent to 10 percent,
will
be
a
popular
choice
in
the
United
cleaning the gas from the kilns. Formerly,
according to McIlvaine.
States.
For
Cement
MACT
rule
Relative
to
electrostatic precipitators were used for
Kerogen (organic chemical compounds)
NOx
control,
selective
non-catalytic
reducthis application. For many years, fabric filin the limestone calcined to make cement
ters have been used for coal grinding and
tion is expected to be the most popular
choice. However, the equipment cost is
is vaporized and, as a result, forms toxic
material-transfer points. McIlvaine says
organic air pollutants. The EPA expects
large cement plant suppliers are frequently low. The big cost is in the area of ammonia injection.
many plants to install thermal oxidizers to
furnishing fabric filters as an integral part
There is also expected to be a signifidestroy these emissions.
of new plants they are building, regardless
June 2011
Flow Control
FOR ALL THAT Runs THROugH iT, THink AbOuT wHATs beHind iT.
Your livelihood runs through it. Whats behind it can make all the difference.
If its a flowmeter from Hoffer, you can be sure its precise, dependable,
and robust. We bring 40 years of proven product performance and a passion
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news & notes

trendlines
Process Automation Market to Continue Recovery Through 2011

Promising signs continue to point toward
a sustained process automation market recovery to continue through 2011,
according to a report by ARC Advisory
Group (arcweb.com). During 2010, the
automation market was at the point where
suppliers serving the installed base with
MRO activities fared better than those
relying heavily on project business. As
such, ARC says suppliers ate through a
huge chunk of their project backlog and
finished product inventory while new projects were postponed or cancelled during
the recession.
Also, shipments for many new project
orders received during 2010 were delayed
until 2011. ARC expects the tepid growth
seen during 2010 to accelerate in 2011,
but remains skeptical about the process
automation market reaching pre-recession
growth levels. Historically, the process
automation market has been characterized
by slow yet steady growth, and ARC says
it expects the market will return to this
pattern with an overall CAGR (compound
annual growth rate) of roughly 6 percent
over the five-year period of 2009-2014.
Suppliers with quick access to raw materials and components and an efficient
supply chain to enable quick ramp-up of
production and inventory will be in the
best position to participate in the increase
in demand, notes ARC.
Purchasing managers indexes (PMIs)
provide a good barometer of overall health
in the manufacturing and automation
markets. PMIs typically include data, such
as production level, new orders, supplier
deliveries, inventories, and employment
level. A PMI reading below 50 indicates a
general contraction in the manufacturing
economy being measured, while any reading over 50 indicates expansion. The J.P.
Morgan global manufacturing PMI edged
up to 57.8 from 57.1 in January, marking the second-fastest reading ever in the
global gauge, which is based on other
surveys covering over 7,500 purchasing
managers in nearly 30 countries.
Output and new order components
accelerated, and the input price gauge
rose to 76.7 from 73.3 in January, according to ARC. The U.S. ISM represents 28.6
percent of the gauge, followed by Japan
Automation Expenditures for

Process Industries by Region
ASIA
LATIN
AMERICA
NORTH
AMERICA
EUROPE, M. EAST, AFRICA
Source: ARC Advisory Group
at 12.3 percent, China at 7.4 percent,

Germany at 5 percent, and the UK at 4.2
percent.
As the economy recovers, ARC says
automation suppliers must make plans to
make the necessary changes and emerge
as stronger organizations that are able to
meet renewed demand. However, this confidence will only come if there is a clear
understanding in their organizations about
the long-term trends that drive demand
for automation and develop strategies to
satisfy those demands.
best practices & standards
Fieldbus Foundation Releases Flow Transducer Block Specification

The Fieldbus Foundation (fieldbus.org)
released the FOUNDATION fieldbus Flow
Transducer Block Final Specification (FF908 FS 1.0), which includes a standardized flow transducer block with a totalizer
function. This specification is designed
to enable greater consistency in fieldbus
device setup, configuration and maintenance, and to make it easier for end-users
to utilize instruments from a range of
automation equipment suppliers.
Transducer blocks are an integral part
of FOUNDATION technology, providing
diagnostic and maintenance data such as
calibration dates. They also provide information regarding the measurement principle used, such as a Coriolis flowmeter
or a differential-pressure transmitter. The
transducer block provides a link between
8
June 2011
the local input/output blocks required to

read sensors and command output hardware from the function blocks.
The Fieldbus Foundations Flow
Transducer Block Specification includes
standard definitions for the following flow
transducer blocks:
Standard ow with calibration for
basic device access
Standard ow with calibration for
complex device access
Common practice parameters for
extended functionality
In addition, the specification provides a
schematic of blocks, parameter access,
and details for handling status of input
parameters. When used in conjunction
with a flow transducer block, the new
totalizer function block supports the time-
critical procedure of totaling different

inputs in order to compute flow.
According to the Fieldbus Foundation,
finalization of the Flow Transducer Block
Specification provides greater predictability in fieldbus implementation, while
reducing integration risks and simplifying
device replacements.
The Fieldbus Foundation has also
announced updates to its other transducer
block profiles, including temperature and
pressure transducer block profiles. The
FOUNDATION fieldbus Device Description
(DD) Library has been updated to integrate
these new transducer block capabilities.
The DD Library includes standardized
source code for all FOUNDATION fieldbus
blocks and parameters.
Flow Control
The
parts
are
8 weeks
out...
How do
you tell
your
customer?
The part you need to keep your business moving is 6 - 8 weeks away. Your customers wont wait that
long, why should you? Alicat Scientific offers all of its standard mass flow and pressure products on a
7 business day lead time. If thats not fast enough, we even have expedited service that gets a product
out the door in 2 business days. We know you have a business to run and we do what it takes to help
you keep it running. Call us at 888.290.6060 or visit www.alicatscientific.com
Innovative Flow and Pressure Solutions
7641 N. Business Park Drive

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Ph: 1.888.290.6060
Email: info@alicatscientific.com
Web: http://www.alicatscientific.com
Alicat Scientific, Inc. is a Halma Company Alicat Scientific, Inc. 2011
applications corner
by David W. Spitzer
Part IV: Vortex Flowmeter Postmortem

Taking Another Look At an Application Gone Wrong
or the past few months, I described problems with a new

installation of an insertion vortex-shedding flowmeter. (See
Applications Corner - Feb., Mar., May.) Not only were the
physical properties of the liquid specified and configured incorrectly, but the flowmeter was installed in a different size pipe as
well. If you have been around for a while, you have undoubtedly
seen similar problems where specifications are incorrect, configuration is incorrect, and/or the device is not installed as planned.
Looking back, this application and installation had multiple problems, but you might not think that to be the case if you followed the
issues in sequence. First, the flowmeter was reported to be measuring low. Apparently nothing else was wrong, but after the flow
measurement was corrected, the flow measurement repeatedly
dropped out. My client initially observed both symptoms, but he
chose to initially report only the measurement error as a problem.
The second problem (drop out) was not mentioned until the
first problem was resolved. Had my client mentioned the second
problem in conjunction with the first problem, he would not have
Filter Trans Ad 4.625x4.875_2011 Filter Ad 3/2/11 2:29 PM Page 1
had
to expend as much time, effort and resources to have a
Situations where more than one problem

exists are typically more difficult to identify and resolve than their single-problem
counterparts. This can be especially
frustrating when one of the problems
turns out to be fatal to the application,
such that the instrument will not work.
technician visit the plant to obtain information that was relayed

to the representative and, afterwards, to the factory. Similarly, the
factory would not have had to diagnose the first problem only to
be confronted with a second problem that rendered the flowmeter
marginally operational in this application.
Situations where more than one probNEW!
lem exists are typically more difficult to
identify and resolve than their singleproblem counterparts. This can be especially frustrating when one of the problems turns out to be fatal to the applicaMiniature Differential Pressure
tion, such that the instrument will not
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pletely and train them to share all of their
For liquid or gas filtration
observations with you this will allow
you to better help them. FC
Filter Transmitter
Transmitter
Transmitter & indicator
www.orangeresearch.com
1-800-989-5657
David W. Spitzer is a regular contributor

to Flow Control with more than 35 years of
experience in specifying, building, installing, startup, troubleshooting, and teaching process control instrumentation. Mr.
Spitzer has written over 10 books and 150
technical articles about instrumentation
and process control, including the popular
Consumer Guide series that compares
flowmeters by supplier. Mr. Spitzer is a
principal in Spitzer and Boyes LLC, offering
engineering, expert witness, development,
marketing, and distribution consulting for
manufacturing and automation companies.
He can be reached at 845 623-1830.
www.spitzerandboyes.com
10
June 2011
Flow Control
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PERFORMANCE:
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installation guidelines
Mission Possible
Analog-to-Digital Valve Upgrades
ook around your home or office, and its obvious to see the
world has become digital. In fact, digital is no longer a
buzz word, because so many of the things around us have
become digital. Do you refer to the radio in your car as a digital
radio? No. You simply say radio. Why? Because unless it is a
classic car, it is assumed that the radio is digital, so the adjective
is unnecessary. In fact, you may find yourself having to describe
something as analog because that is no longer the norm.
A similar transformation is underway in process control, as
a wide variety of new digital devices have been introduced in
recent years, and a growing number of facilities have installed
them. The transition is still a work in progress, however.
Some process control facilities have simply been a bit slower
to adopt digital valve positioners, for example, as they seek to
become more comfortable with this unfamiliar technology. Others
have made the switch to digital devices, but have maintained an
analog mindset and use the digital positioners as they did their
analog predecessors. Returning to the car radio analogy, they
have the latest Bluetooth-, satellite- and MP3-enabled system,
but only use it to listen to a half-dozen local radio stations.
In either case, the result is the same. The status quo is maintained and technologies that could help plant operators save time,
money and frustration while potentially improving product quality
and enhancing safety, are either not adopted or are underutilized.
The first step in making the transition to digital valve positioners is understanding how they can be easily and cost-effectively
implemented in a facility. This article will begin to bridge that gap
by reviewing the various technologies available and highlighting
the steps that should be taken to help ensure a successful transition. In addition, it will explain how plant operators can achieve
what many consider to be a mission impossible i.e., hot
cutover, or switching to a digital valve positioner while the process workflow continues uninterrupted.
Why Move to Digital Valve Technology?
technology to that of digital control technology should be considered a permanent move. As this article will highlight, this permanent transition can provide significant benefits. But, as when
considering any permanent move, plant personnel should ensure
they have a clear understanding of the advantages and disadvantages before proceeding.
There is one very simple reason to consider going digital to
be competitive in todays completely connected world. Processing
plants, whether they produce power, raw materials, or finished
products, are under constant pressure to maximize their operational excellence a combination of profitability, plant efficiency, quality, and safety in a tightly interconnected global economy. Digital
valve positioners can help process plants meet these challenges by
quickly and precisely giving them the information they need.
A poorly performing $3,000 control valve can cause significant
losses because of shutdowns, lost production, reduced efficiency,
and unsafe events. Such losses can be reduced with digital
valve positioners because they have fewer moving components,
are self-calibrating, and can provide diagnostic information that
allows plant personnel to monitor valve health more easily. The
outcome is improved control valve reliability, repeatable and sustainable performance, and detection of valve degradation before it
impacts the process and while it is more easily corrected.
Digital Valve Positioning Technologies: The Options
Digital valve positioners (DVPs) can be divided into two categories: hybrid and fully digital.
Hybrid positioners use an analog signal (current) as a command signal while superimposing over that signal a frequency
that allows for bi-directional communications. The HART Protocol
is one example of a hybrid protocol.
In fully digital implementations, the command signal is provided in a binary form that is coded and decoded by a communication protocol. The FOUNDATION Fieldbus and Profibus PA
protocols are examples of fully digital technologies for DVPs.
Moving a process control plant from the world of analog control

CV with bypass line
CV with hand wheel
CV without bypass / hand wheel
Hybrid Positioners: The Pros and Cons
Hybrid DVPs offer several benefits for end-users who want to

get their feet wet with digital technology without diving all the
way in.
Implementing hybrid positioners is less disruptive than
MARSHALLING RACK
MARSHALLING RACK
MARSHALLING RACK
implementing fully digital devices because existing assets and
JUNCTION BOX
JUNCTION BOX
JUNCTION BOX
infrastructure, such as the controller, cabinets and wiring, are
Tx
Tx
Tx
retained. End-users can quickly benefit from increased uptime
and reliability with less engineering effort and a smaller capital
C.V.
C.V.
C.V.
Bypass valve
investment.
Sustainability is another key advantage of hybrid installaFigure 1. Three typical control valve installations. The process of moving to
tions because what controls the valve the analog signal is
digital positioners will be easiest in the scenario on the left and most challeng- unchanged, and that familiarity means less additional training
ing in the situation on the right.
is required in order to troubleshoot, retrofit or replace the DVP.
Controller
Controller
Controller
HW
12 June 2011
Flow Control
By Sandro Esposito
The key advantage
Calibration Relationship Between a Digital Valve Positioner and a Control Valve of a fully digital DVP
Utilized Sensor Range
Valve Calibrated
Travel
DPVs Available
Travel Sensor Range
implementation is that information moves

seamlessly back and forth on the communiInstall
n
a
DVP
100%
llatio
Trimm tion
cation bus. In a hybrid system, information
Instaffset
SPAN
in
g
O
Open
only travels between the positioner and the
50%
50%
controller. In a fully digital implementation,
Actual
45%
it also travels between devices. As a result,
the information can be used by all assets
Plug
DVP
Close
ZERO
within the control structure, helping make
0%
Seat
process control smart and robust.
This complete and unobstructed view of
Available
Utilized
Position
Hot Cutover
Hot Cutover
Travel Sensor Travel Sensor
vs
Feedback
Feedback
the process and control system assets is
Range
Range
Setpoint
Installation
Adjustment
one reason that designers of greenfield (or
DVP Setup
Control Valve Hot Cutover Setup
new construction) projects consider fully
Figure 2. This chart illustrates the relationship between a DVPs digital feedback and the true medigital systems. In a hybrid installation, each
chanical position of a valve. A DVP has an available range to measure a displacement of the valve. valve is wired separately and each wire must
A portion of that available range will be utilized by the DVP.
be individually tested during the commissioning process. With potentially hundreds of
Along the same lines, unlike an analog positioner, a DVP can guide valves in a facility, that process can be extremely time-consuming.
the end-user in the setup and troubleshooting processes because it
In a fully digital implementation, however, several control valves
provides continuous information about its condition. As a result, less
can feed off of a main communication trunk, so there is only one
time is spent guessing what could be causing a problem, and the
test setup required to test several valves. The commissioning proteam can more quickly move on to resolving the problem.
cess is streamlined and the facility is up and running sooner.
On the minus side, hybrid technology will eventually become pass,
In addition, a completely digital implementation enables predictive
so it is not a matter of whether the transition to fully digital devices will maintenance. According to an ARC Advisory Group (www.arcweb.
be made, but when.
com) study, The real value of fieldbus is Operating Expenditure
(OpEx) related rather than Capital Expenditure (CapEx) related. EndFully Digital: The Advantages and Disadvantages
users have reported that predictive maintenance is the single largest
A fully digital implementation requires a complete replacement of savings resulting from the use of fieldbus. (Fieldbus Solutions in
the process controllers because the control signal to the DVP is
the Process Industries Worldwide Outlook, Paula Hollywood, 2007.)
no longer analog, but strictly digital. Upgrading to fully digital is,
This makes sense when you consider that control valves are
therefore, a bigger leap, but can also bring additional benefits.
a contributor to plant efficiency and make up a large portion of a
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June 2011 13
facilitys maintenance budget.

Hot Cutover of Digital Valve Positioners (Use Cases and Flowchart)
A fully digital DVP can provide
Handwheel
Configuration
alerts and key valve health
Existing
Destination or Positionand Calibration
Case
#
Case
Type
indicators, allowing plant
Positioner
Positioner
blocking
Data Avalable for
Device?
Destination DVP?
personnel to plan ahead using
actionable information.
1
Yes
Yes
These are powerful advan2
No
Migration
tages, but they do come with
Any
(Re-instrumentation)
3
Yes
additional challenges. The
No
4
No
disadvantage of a fully digital
DVP
positioner is that it is com5
Yes
Yes
pletely digital. The operator
6
No
Replace Existing
DVP
must, therefore, understand
Positioner
7
Yes
No
the ramifications of bytes and
8
No
bits. He or she does not need
to know what 111101010
Figure 3. The success of any mission hinges
stands for in order to make
on having the right tools and a solid execuManually
DVPs
a DVP work with the control
tion plan. This flowchart of the hot cutover
No
configure
configuration information
process identifies the essential questions to be
loop, but does need addiDVP
available?
answered, the key steps in the process, and the
tional software and computer
necessary tools.
YES
skills to set up and commission a fully digital device
Based on actuator
because it is software that
travel, determine
Validate upper and
enables communication
upper and lower
lower stop values
calibration stops
between the DVP and the
other digital assets. If a digital positioner is not properly
Load in DVP upper
and lower calibraset up and integrated with
tion stops and other
parameters
the other assets, it will not
be able to respond to a command signal.
Handwheel
Remove air
No
or manual handjack
Set tight shutoff
to valve
As a result, there are more
available?
of 5%
parameters to understand
and to set up properly. On
Yes
Lock valve with
average, a fully digital DVP
handwheel or handjack
and read valve
has 500 parameters with an
position in %
End
average of four possible settings for each parameter or
2,000 possible combinations.
Adjust feedback mechaApply air supply
Slowly disengage
Remove old
nism so that position
and set loop
In contrast, a typical hybrid
Install
DVP
handwheel or
positioner
displayed by DVP matches
current to match
handjack device
device (with HART communilocked position
locked position
cation) has 120 parameters
with an average of three choices per parameter just 360 possible
Situation 1: Offline While the Process is Down or the Valve
combinations. In other words, setting up a fully digital DVP is a more Is Isolated
complex process, and while it is not rocket science, it does require
When installing a hybrid DVP (4-20mA with HART), an important
proper training.
consideration is whether or not there is an existing 4-20mA signal
available at or near the valve. Very little engineering is required
Making the Move: Going Digital
if there is an existing signal going to a current-to-pressure-conWith adequate preparation, the move to digital technology can be
verter (I/P converter) or an electro-pneumatic positioner. In most
completed successfully while the process is running (online) or
cases, the engineering involved will be related to management of
during a shutdown (offline). A hybrid implementation can be done
change (MOC) because the DVP will replace the analog positioner
with the existing control system in place, while a fully digital situusing the existing wiring.
ation requires installation of a completely new control system that
If the process is running but the valve can be isolated
is capable of digital communication, such as FOUNDATION Fieldbus (bypassed), it is best to take advantage of remote digital commuor PROFIBUS.
nication. Once the mechanical installation has been completed,
14 June 2011
Flow Control
personnel can move to a safe area to carry out the calibration,

preventing unnecessary exposure to a potentially hazardous process environment.
In a fully digital implementation, additional engineering will
be required prior to the installation, as the DVP will be digitally
integrated with the process control system. This engineering
typically consists of:
Determining whether there are available addresses for the
DVP on the communication segment. Every device on a segment must have its own digital address so that it can exchange
information with each of the other devices on the segment.
Quantifying the total execution time of the loop. In most
control loops, one second is needed to process the measured variable and provide a command signal to a final control
element. But some loops, such as flow and pressure, require
quicker execution. In these cases, adding multiple DVPs may not
provide for robust control.
Identifying the function block within the DVP that will be
necessary for each process control loop. For instance, it is
necessary to determine whether the process PID will reside in the
DVP or elsewhere on the communication segment. If the PID will
reside in the DVP, the parameters for process control must be
carefully reviewed and determined in advance.
1
2
tem can be easily adjusted so that it also reports

out 25 percent.
Figure 2 illustrates the relationship between a DVPs digital
feedback and the true mechanical position of a valve. A DVP has
an available range to measure a displacement of the valve. A
portion of that available range
will be utilized by the DVP.
Of course, the success of any
mission also hinges on having the right tools and a solid
execution plan. The flowchart in
Figure 3 identifies the essential
questions to be answered, the
key steps in the process, and
the tools that will be required
to upgrade to digital technology
while the process is live.
Situation 2: Online While the Process is Running (a.k.a.

Hot Cutover)
If the process cannot be shut down, it is still relatively easy to
replace an analog positioner with a digital device. This technique
is known as hot cutover or online installation.
Many plant operators still see hot cutover as mission impossible, and it is indeed so when replacing one traditional analog
positioner with another. Several refineries and petrochemical plants
have, however, successfully replaced analog positioners with hybrid
devices while the plant was in operation, avoiding significant losses
in production that would have resulted from a plant shutdown.
End-users have also successfully completed mission impossible 2 migrating from a completely pneumatic control system to
a fully digital system while the plant was running. The key to this
capability is that, when working with DVPs, little or no mechanical
adjustment is necessary and the zero and span can be preset.
This allows the replacement of a pneumatic positioner with a DVP
without moving the valve for calibration purposes.
In such cases, the valve must be isolated, be locked in its existing position, or remain in its failsafe (open or closed) position. It is,
therefore, recommended that the DVP be configured and calibrated before work begins at the valve, thus minimizing the amount of
time that the valve will be isolated or manually locked in position.
What makes hot cutover possible is that a DVPs zero and span
are not mechanical. There are no screws to turn, beams to balance or springs to adjust when setting the starting and ending
points that correspond to 0 percent to 100 percent travel. The
zero and span are set digitally and the DVPs feedback mechanism is adjusted to match the actual position of the valve. For
example, if the mechanical position of the valve reads 25 percent
after the zero and span have been set, the DVPs feedback sys16 June 2011
Figure 4. Digital valve positioners

provide reliable process control in
severe service applications, such as
the installation shown in this photo.
Considerations for a
Successful Move to
Digital Devices
Whether upgrading to hybrid or

fully digital technology, the following are some key considerations to keep in mind.
Wiring/Power: An analog positioner requires 2-3 Vdc, while
a DVP can require up to 12 Vdc. Not all legacy control systems
are capable of providing a 4-20mA command signal to a DVP that
requires 12 Vdc. This power shortage is even more likely to occur in
split-ranged control valve applications in which a DVP is replacing
two analog positioners connected in series.
When specifying a DVP, and before removing the old analog positioner, plant personnel should verify the maximum load that the controllers output is capable of and choose the DVP accordingly. If the
voltage is still insufficient, particularly when installing two positioners
in series, a signal conditioner with more voltage will be necessary.
In a fully digital implementation, proper wiring is essential
because it greatly affects the quality of the digital signal. If the wiring is not properly grounded and terminated, signal quality will be
compromised and communication between devices will be slow,
affecting every device on the communication bus.
Number of DVPs: The greater the number of DVPs that
are installed on the same wire, the greater the risk that multiple
control valves will be taken out of service if power is lost to that
bus or if the main trunk for that bus is broken. A good rule of
thumb is to have no more than three valves per segment and, in
key applications and extremely fast process control loops, to have
only one valve.
Training/Personnel: When planning an upgrade to a fully
digital system, plant personnel must allocate adequate time and
resources for training the in-house team. Otherwise, once the
installation has been completed and the vendor has moved on to
the next project, they may quickly realize that they do not have the
knowledge required to support and maintain the new system. It is,
therefore, imperative that a detailed training program be included
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in the upgrade plan and that the program include ongoing training
until the team is comfortable working with the devices.
Most DVP manufacturers offer product training programs, and
excellent courses are available through a variety of colleges and
through the Instrument Society of America (ISA, www.isa.org).
These programs teach attendees how to mount and set up the
DVP, how to commission the DVP using a handheld device, and
how to troubleshoot.
The training required to work with hybrid installations is more
straightforward, as the command signal is similar to that of an
analog device and special system configurations are not necessary to make the valve work with the control system.
Support Tools: A basic 4-20 mA signal generator and voltmeter are not sufficient to support a hybrid or fully digital installation with DVPs particularly a fully digital installation.
While some 4-20mA HART positioners can be set up locally at
the device when equipped with an LCD or local buttons for setup
and calibration, others require software with a HART modem or a
portable handheld calibrator capable of communicating with the
DVP. The setup process, thanks to the digital positioners userfriendly interfaces and ability to provide troubleshooting information is significantly streamlined compared to that associated with
setting up an analog positioner.
A fully digital DVP will also require a special power supply,
a handheld device or computer with digital communication, a
modem, software, and communication analyzers. These tools are
readily available, and it is only a matter of planning and budgeting
for such tools when developing the project scope.
Loop Tuning/Control System Adjustments: Imagine a
four-cylinder engine in a midsize car. You have driven this car for
years, and you have the habit of putting a certain amount of pressure on the gas pedal when passing another car or starting after
a complete stop. Now, put a more powerful and efficient eightcylinder engine in that same car. There is a good chance that, if
you hit the gas pedal the same way, the tires will screech. Worse,
you might bump into the car in front of you.
The same theory applies when retrofitting a DVP on a control
valve that is already installed in a plant. The old analog positioner
may not respond until the signal changes by 1 percent or 2 percent or even more, and it may not be as quick and accurate when
positioning the valve. But the loop is tuned and optimized based
on those performance characteristics. In contrast, a DVP, with its
precise feedback sensor, fewer mechanical moving parts, and
fast control algorithm, may respond to a command signal as low
as 0.1 percent and move the valve much faster and with greater
accuracy. The control valves dynamic response has dramatically
changed and, as a result, the loop tuning is likely too aggressive
for this new control valve behavior.
The worst response to this problem would be to detune the
DVP and make it perform like a four-cylinder engine. Doing so
would defeat one of the purposes of moving to a digital device
greater plant performance. The best practice is to involve the
process control engineer when moving from an analog device to
a digital one and work as a team to maximize the control valves
overall performance.
18 June 2011
Putting the DVPs Data to Work
As mentioned earlier, end-users have reported that the

ability to conduct predictive maintenance is the single biggest contributor to the savings that result from the use of fieldbus. The key is
a DVPs ability to provide easy access to diagnostic information.
Figure 6. The facility shown here features a combination of valves that

have been retrofitted with hybrid positioners and valves that retain the
original analog positioners.
In hybrid installations on older control systems, the use of wireless technology can cost-effectively link the DVP and the asset
monitoring tools. Newer controllers can communicate with hybrid
DVPs without the intermediary of wireless technology. Fully digital
DVPs can literally put terabytes of process information at plant
personnels fingertips.
The data is most valuable, however, when it is delivered with
actionable information that is then put to use. When upgrading
to digital valve technology, facilities must also invest in the tools
such as plant asset management software and online valve
monitoring tools needed to capture, consolidate and present the
information in an actionable format.
Plant personnel must also adapt their workflows (and often
shift their mindsets) to embrace these new tools. Too often, digital devices are installed and then gather dust as habits remain
unchanged and the available data is not accessed and acted upon.
The world around us has become digital. In so many ways,
that emigration has made us more productive and efficient, made
our day-to-day lives easier, and made the things we use every
day more powerful, reliable and user-friendly. The same thing
could happen in the process control world, thanks to todays digital valve positioning technology. All it takes is a bit of planning
and a willingness to start the journey. FC
Sandro Esposito is Global Marketing Manager for digital and
SMART products at GE Energy. A 17-year veteran of the control
valve and process automation industries, he has extensive experience with control valve diagnostics and system integration. He
has been granted several patents related to digital valve positioners. He graduated from Ahuntsic College in Montreal with a
degree in instrumentation and process controls. Reach him at
sandro.esposito@ge.com or +1 281 671-1683.
www.ge-energy.com
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2011 flow control innovation awards

Photo courtesy of Apple
(www.apple.com)
And the Nominees Are
Recognizing Fluid Handling Technology Innovation
he following technologies represent the final nominees for the 2011 Flow Control Innovation
Awards program. Nominees include novel technology solutions for fluid handling applications
in the categories of fluid measurement, control and containment. Please review the technology
summaries provided below, and visit FlowControlNetwork.com for more information on how to place
your votes for the Innovation Awards nominees. You can vote for up to five products, and all voters
will be entered into a random drawing to win an Apple iPhone 4G. Innovation Awards winners will be
announced in the September issue of Flow Control, with extended case studies/application stories on
each of the winning technologies featured in the October issue. If you have questions and/or require
additional information on any of the technologies highlighted below, please contact Matt Migliore at
610.828.1711 or Matt@GrandViewMedia.com. Thanks for supporting the Flow Control Innovation
Awards program. Voting Deadline: Noon EST, Aug. 1
MEASUREMENT
Differential Pressure-Based Multi-Fluid Meter
Camerons differential pressure-based
NuFlo Cone Meter is a process control
and multi-fluid meter that is designed
to provide accurate, repeatable, and
cost-optimized measurements. The
meter is able to fit into small spaces
while offering large and stable turndowns with high levels of accuracy and repeatability. It is designed
to work in both unprocessed and processed applications and is a
good fit for upstream, midstream and downstream scenarios that
present a wide range of measurement challenges. The device also
offers an economic, compact design, low cost of ownership, and,
since there are no moving parts, a long, virtually

maintenance-free lifespan.
The NuFlo Cone meter features a hydrodynamic design for easy installation and no moving
parts. The design enables a cleaning (or sweeping) effect from the velocity increase in the throat
and around the differential producer. The cone
meters easy installation and compact size is an
advantage when used in an offshore platform process, reducing
costs and installation time. In addition, the meter is manufactured in
a facility that is ISP 9001, API 22.2-certified, and GOST-approved for
natural gas custody transfer in the Russian Federation.
vote for this technology @ www.flowcontrolnetwork.com
Aluminum-Bodied, Dual-Rotor Turbine Flowmeter

COX Flow Measurements
s ALDR is an aluminum-bodied, dual-rotor turbine flowmeter intended for automotive and aerospace
applications. Its unique design incorporates
an integral ExactComp EC80 flow computer
and embedded pickoffs, enabling smaller
packaging, lighter weight, and greater reliability in high-vibration installations.
Aluminum construction creates rotorblade sensing issues, which are overcome
by the use of a high-sensitivity amplifier with
coupling and processing characteristics. Plus,
the meters smaller packaging, lighter weight, and
embedded pickoff coils work well in small areas subject
to high vibrations. Combine this with extended-life ceramic bear-
ings and precision primary standard calibrations, and the meter

provides top performance for competitive and critical measurement applications.
The ALDR design utilizes a 100-ohm RTD to measure
fluid temperatures and correct for fluid viscosity variances.
The flow computer takes full advantage of the capability and
provides a corrected flow output, which is enhanced by
the dual rotors ability to extend the UVC usable flow
measurement range. Embedded pickoff coils withstand vibration typically found in the automotive
and aerospace industries by reducing mass and
size. This design does not employ flow straighteners since the dual-rotor cancels out fluid swirl
effects, delivering a flowmeter package that will fit in limitedspace scenarios.

20 June 2011
Flow Control
Photo courtesy of Apple

(www.apple.com)
VOTE to WIN an iPhone 4G
When placing your votes for the 2011 Flow Control Innovation Awards, you will have the
opportunity to automatically enter a random drawing to win a $199 Apple iPhone 4G gift card.
The gift card covers the current retail price of an 16GB iPhone 4G, or you can use it for any
other product in the Apple Online Store or any Apple Retail Store.
Voting Deadline: Noon EST, Aug. 1
Mass Transmitter for High-Speed, High-Accuracy Dosing

Emerson Process Managements Micro Motion
Filling Mass Transmitter is specifically designed for
high-speed, high-accuracy filling or dosing. Utilizing
Micro Motion MVD (multivariable digital) technology, the transmitter, combined with a Micro Motion
Coriolis sensor, is ideally suited for a variety of
linear and rotary filling machines across the
life sciences, food and beverage, and chemical
industries. The transmitter can handle extremely
fast fills (less than one second), very small fills (<1ml),
and challenging fluids, such as those with entrained air,
suspended solids, or high viscosity.
With increasing pressure on production quality efficiency and
throughput, traditional volumetric- and meter-based technologies
are no longer sufficient. Micro Motion filling meters deliver mass,
density and temperature process data in one device,

supporting continuous monitoring of product quality
with a complete real-time view of fluid characteristics. Digital communications provide continuous
monitoring of density and temperature for real-time
quality control, and enable on the fly changes
to fill target or recipe.
The transmitters Automatic Overshoot
Compensation (AOC) feature automatically
adjusts valve management to compensate for changes
in process conditions to deliver accuracy and reliability
with minimal setup and maintenance. With direct mass
measurement and superior stability (turndown), the Filling Mass
Transmitter is suitable for filling a variety of container sizes and
products with a single sensor.
Two-Wire, Loop-Powered Coriolis Flowmeter

Endress+Hausers Promass E 200 is a true two-wire,
4-20 mA HART, loop-powered Coriolis meter for mass
flow and density measurement. Through the use of
patented Adaptive Power Techniques, the Coriolis flowmeter is able to provide continuous, accurate and reliable
measurements without the need for converters, custom power supplies, or barriers. The
Promass E 200 is the ideal flowmeter for continuous process control, offering a high level
of safety and reliability, compliant to SIL-2 and
SIL-3, with an intrinsically safe and explosionproof design approved for Class 1 Division 1
applications. By combining Coriolis technology with the
reliability of two-wire integration, a favored cost-effective measuring solution now exists that fulfills the high safety standards in
addition to the industry-specific requirements.
Coriolis mass flow technology has historically been contained
to traditional four-wire power/signal methodologies due to the
need to power the sensor, amplifier, transmitter, and

outputs. The Promass E 200 is innovative in that
it maintains the highest levels of Coriolis accuracy
and reliability while operating under a two-wire,
loop-powered concept, which significantly limits the
available power to the Coriolis meter.
In addition to the Adaptive Power
Techniques used by the Promass E 200, this
product line has set a standard for commonality across the Endress+Hauser flow and
level product lines. The two-wire product lines
from E+H will now share common Human Machine
Interface, spare parts, and electronics modules. The new
HistoROM capability provides an onboard nonvolatile device
memory that enables data management and automatic data
backup for device configuration. The HistoROM offers extended
functions for an embedded event logbook, including the data logging for over 1,000 points.

FC-0611-FA.1.indd 21
June 2011 21
6/15/11 1:20 PM
Thermal Mass Air/Gas Flowmeter

Fluid Components Intls ST100 Series is a thermal
mass air/gas flowmeter that provides a graphical user
readout, an on-board optically activated keypad, a
comprehensive selection of analog outputs and bus
communications, a pressure measurement option,
dual-element configurations, multiple calibrations, 10
user-selectable gas calibrations, a built-in data logger, and
a robust transmitter. It also features a selection of flow elements matched to a users application, temperature service
up to 850 F [454 C], can be configured with FCIs VeriCal insitu calibration verification system, and is available in both
integral and remote configurations up to 1000 feet (300m).
The typical readout/display in this segment is a small character, two-line LCD. With the ST100, the user gets graphical/
digital, backlighted LCD readout, which continuously displays
all measured parameters, flowrate, total flow, temperature

and pressure, plus flowrate in a 0-100 percent bar graph and
the active calibration group. For alarms, icons illuminate and
flash upon a trip condition and will change to steady-state
when acknowledged. The display also has an innovative writeable field in which the user can note gas composition, application
name, pipe or process name, or even a tag number for quickly
associating the readings with the correct process. Another unique
feature of the display is that it is rotatable electronically by the user
to ensure the optimum viewing angle.
The meter offers outputs of analog and bus communication,
including triple 4-20mA, frequency/pulse, relays, HART (version 7),
Foundation Fieldbus, Profibus-PA, and Modbus.
The meter provides accuracy to 0.75 percent of reading (compared to the 1-2 percent typical in this product segment).
Radar Level Transmitter for Continuous & Point-Level Measurement

Flow Line Options Corps Tracer 1000/2000 GuidedWave Radar Level Transmitter is designed to provide
continuous radar level measurement and point level
detection in liquids and solids, with analog and
switching output. The Tracer 1000/2000 is well-suited
for a range of measurement applications and has almost
no installation restrictions. The device can be mounted in
small tanks, tall and narrow nozzles, and it measures precisely even with difficult tank geometries or close to interfering
structures.
Outstanding operating characteristics include:
Unstable Process Conditions: Changes in viscosity, density, or
acidity do not affect accuracy.
Agitated Surfaces: Boiling surfaces, dust, foam, and vapor do
not affect device performance. Suitable for recirculating

fluids, propeller mixers, aeration tanks.
Extreme Operating Limits: Performs well under
extreme temperatures up to 600 F (315 C). Capable of
withstanding pressures up to 580 PSIG (40 Bar)
Works with Fine Powders & Sticky Fluids: Vacuum tanks
with used cooking oil. Paint, latex, animal fat, and soy bean
oil. Saw dust, carbon black, titanium tetrachloride, salt, grain.
Testimonial: The new radar system works really good;
I would like to use it in a few lift stations. The [Tracer
1000/2000] is better than other products used in the past, plus
there is no concern with mist. Kevin Smith, Chief Operator at
New Philadelphia WWTP.
Differential Level Transmitter for Barscreen Level Measurement

Greyline Instruments DLT 2.0 Differential Level
Transmitter is a simple solution for barscreen
level control at wastewater treatment plants,
pump stations, and combined sewer systems.
With non-contacting ultrasonic sensors positioned up and downstream from a barscreen,
the DLT 2.0 can display and transmit differential level. The downstream sensor can also be
installed above a flume or weir to measure and
totalize open-channel flow.
Greylines DLT 2.0 reduces costs and simplifies instrumentation at treatment plant headworks. Two sensor
differential instruments have been in service for some time, but
the DLT 2.0 feature of combining one of the sensors for the dual
function of both downstream level and differential flow is a unique, cost-saving design that
eliminates the need for a dedicated open-channel
flow monitor. Until the DLT 2.0 was developed,
treatment plants would have to buy two separate
instruments to accomplish the same functions.
The DLT 2.0 Differential Level Transmitter measures level and open-channel flow with +/-0.25
percent accuracy using two non-contacting ultrasonic sensors. It is calibrated with a user-friendly
keypad/menu system and includes fully programmable control relays plus three 4-20mA outputs for upstream
level, differential level, and downstream level or open-channel
flow. Plug-and-play data storage options are available.

22 June 2011
Flow Control
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Filter/Meter Package for Ink Filtration/Metering

INKnet Systems INKsmart is a filter meter package system.
The first in digital plug-n-work technology for the
printing industry delivers filtered ink to the printer with
accurate microprocessor-based documentation of ink
consumption. A lightweight package with filter and
meter easily connects to the gear-side of the press
without affecting pre-existing plumbing. One of the
most impressive features of this 0.1 percent meter
is that it requires no calibration out of the box.
The INKsmart unit combines filtration & metering weighing approx. 22 lbs. with package dimensions of 6.5 deep x 8 high x 9.75 long. All data
is captured in real-time with dual outputs both in
(network and digital). The instrument is a production
tool for monitoring flow and consumption rates, time,
and temperature.
Aggressive media filtration and accurate media consumption
documentation is accomplished from the instrument, which is
sealless in design, providing quadrature output without breaching the mechanisms integrity. Its flow range is from 1cc of ink
per minute to a maximum of 15 gallons of ink per minute. It can
operate within temperature ranges is from 50 F to 200 F without
compromising its 0.1 percent accuracy, and it operates effectively from 5 PSI to 4,000 PSI, producing 40 CC of
measured material at 24 pulses per revolution.
The innovative precision meter package with
attached filter filters media with a high-pressure
built-in filter system and no filtration bypass
mechanisms. Filter elements are crush-proof to
4,500 PSI with the filter canister pressure-proof
up to 12,000 PSI.
Testimonial: Ive worked for three different printing companies in my 30 years in this industry. I know
that old technology was helter-skelter for everybody.
Each of the three companies tried to use the old technology, and each one tossed it out. There was a need for
improvement, but the tools werent there. INKnet has bridged that
gap, and its been a very solid, encouraging improvement in the
industry.
Since the original INKnet purchase, Ive never even looked at
any other solutions. Theyve given me exactly what I want. Jim
Burke, Production Manager, Buffalo Newspress.
ProcessFlowDirect_1-4:Layout
vote for this technology @ www.fl
owcontrolnetwork.com
5/26/11
1:44 PM
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24 June 2011
Flow Control
Thin-Film Thermal Mass Flow Sensor for Low-Flow Gas & DP Applications
Innovative Sensor Technologies
MFS02 micro flow sensor is a thin-film
thermal mass flow sensor that is a good
fit for (low) gas flow and differentialpressure applications. Measuring at
just 3.5 x 5.1 mm, the sensor features
platinum micro heaters and temperature
sensors on an ultra-sensitive polymer
membrane. There are four resistance
elements on the chip; two high and two
low. As flow passes over the sensor, the
distribution of heat across the resistors
indicates both the magnitude and direction of the flow. An additional pt1000
RTD temperature sensor can be specified
on the chip for alternate use as a constant temperature anemometer in high
flow applications. The MFS02 is capable
of measuring gas flow and direction in a
range from 0.001 to 2m/s (up to 50m/s),
and has a response time of less than 10
milliseconds. The operating temperature
range for the sensor element is -40 C to
150 C.
The innovation associated with the
MFS02 flow sensor is derived from the
polymer membrane technology that it
employs. Moving from the traditional
ceramic substrates of other flow sensors
to the polymer membrane of the MFS02
has allowed the sensor to make extreme
improvements in sensitivity and response
time. The sensor has a reduced power
consumption compared to older sensor
models due to its low thermal mass. The
MFS02 also impresses when compared
to other competitive technologies on the
market in regards to increased measuring range and operating temperature
range, and improved handling, versatility
and robustness.
Through thin-film deposition and
polymer technology, Innovative Sensor
Technology was able to develop the
MFS02 with outstanding operating characteristics. The first noticeable quality of
the sensor is its miniature size. In combination with the size of the MFS02, the
use of a thin polymer layer exposed to
air on both sides of the substrate at the
active area has led to an extremely low
vote for this technology @

www.flowcontrolnetwork.com
thermal mass. This low thermal mass has resulted

in additional outstanding operating characteristics,
including sensitivity, low power consumption, low
weight, and fast response time. The versatility and
robustness of the sensor construction also lends
itself to both high and low flow ranges, a wide operating temperature range, and a stable zero point at
no flow that is resistant to contamination over time.
Application Experience
Beyond Measure
Nobody knows you like Brooks

When you need flow and level instrumentation for your project, you dont have
time for trial and error. You need the right solution for your exact application
and you need it fast. It needs to just flat-out work now, and for years to come.
Thats why companies across the planet choose Brooks. With over 60 years
of process experience in applications from basic device testing to nuclear
processes and everything in between our people have seen it all. You could
say weve been there, solved that.
So bring your biggest challenges to Brooks
for all your toughest applications.
B
Pick our brains and profit from our experience.
Application Experience
Beyond Measure
1-888-554-FLOW | www.BrooksInstrument.com | BrooksAM@BrooksInstrument.com

June 2011 25
Full-Profile Insertion Magnetic Flowmeter

McCrometers FPI Mag is a full-profile insertion
electromagnetic flowmeter with a fully submersible
sensor, featuring multiple electrodes measuring
flow across the entire diameter of the pipe. The
meter can be installed in line sizes from four inches
to 138 inches and in pressures up to 250 PSI. Each
meter comes standard with an L-Series Converter.
Ease of hot-tap installation: The FPI Mag
flowmeter installs without interrupting service,
de-watering lines, cutting pipe, or welding flanges.
The easy hot-tap installation makes the FPI Mag particularly costeffective for retrofit applications, replacing flowmeters, or in sites
never metered before.
Multi-electrodes deliver accurate full profile: The FPI Mags
unique operating principle delivers accuracy unmatched by other
insertion magmeters and rivals the performance of

a full-bore mag meter. Continuous measurement
across the entire flow profile compensates for variable flow profiles, including swirls and turbulent
conditions.
Robust construction for operational longevity: The sensor body is made from heavy-duty 316
stainless steel for maximum structural integrity.
An NSF-certified 3M fusion-bonded epoxy coating
ensures superior long-term operation.
Virtually no recalibration or maintenance: The FPI
Mags highly stable flow sensor comes pre-calibrated from
McCrometers NIST-traceable calibration lab and requires no
recalibration in the field. With no moving parts, the FPI Mags simply designed sensor contains nothing to wear or break.
Digital Video Camera for Hazardous Sight-Flow Applications

LJ Stars K25-Ex explosion-proof-rated digital video camera is designed for use with a
sightglass on a process vessel and for visual
inspection of pipes. It is ideal for any hazardous
location where operator access to a sightglass
is difficult or dangerous, as well as for remote
locations that require a great deal of time for
operators to reach.
The K25-Ex Camera System is smaller than comparable video
camera systems that must be mounted inside separate, bulky,
explosion-proof housings. It is the most compact camera system
in its class that offers high resolution for precise observation and
the ability to control and contrast captured images.
Testimonials: A safety-equipment company

needed video cameras that were small enough
to fit inside small oil pipelines. Its equipment
is used to verify that the pipes are free of residue before workers begin to repair the pipes
using welders. The cameras that it had been
using were installed inside separate housings
to assure an explosion-proof rating. The bulky
cameras made it more difficult for operators to work around the
reactor, which has a lot of other equipment surrounding it. The
company solved this problem by switching to the L.J. Star K25-Ex
Camera System, which is the only explosion proof-rated camera
system small enough to fit its size requirements that it could find.
Portable Battery-Operated Thermal Mass Flowmeter

Sage Meterings Sage Prism is a portable
battery-operated thermal mass flowmeter with
extensive data-logging capability. Designed
to operate for up to 10 hours on a built-in
rechargeable Lithium-ion battery, the insertionstyle portable flowmeter has 16 independent
calibration channels, and can measure and log
up to 3,800 data points of gas flow in pipes
one inch and larger. The Prism is ergonomically
designed, has an easy-to-read display with navigation buttons,
and can log data in Auto Mode or Manual Mode. The data (Log#,
Flowrate, Temperature, Calibration Channel, Date, and Time
Stamps) is stored within the portable for subsequent uploading
to a PC and saved as an Excel spreadsheet.

Software, charger, and carrying case are all
included.
The Prism is designed to accurately log the
mass flowrate of gases, such as Natural Gas,
Landfill Gas, Digester Gas, Compressed Air, and
Nitrogen. When commanded, the unit will also
output the stored data to a PC. In addition to
having 16 Calibration Channels, the Prism also
can be switched to TAG ID Mode, allowing the user to identify 99
different pipes, which require logging of the flowrate. The unique
Tags that the user identifies for the pipes can be associated with
any of the 16 calibrations (or configurations).

26 June 2011
Flow Control
Thermal Mass Flowmeters for Gas Flow Control

Siargos MF5700 Series mass flowmeters are
designed to provide a digital gas flow control
and/or monitor in product process lines where
rotameters are currently used do to cost considerations.
The meters are manufactured using lowpower MEMS thermal mass flow technology
that can provide digital (Modbus) interface
with a large turndown ratio of 50-to-1 with an
accuracy of 2 percent of readings. The meters
can also be used as a stand-alone unit powered with four AA batteries. The meter head can be rotated 180
degrees for easy data access at any installation conditions. The
meters are sold at below $50 with a volume.
Unlike the volumetric technology, the MF5700

meter provides mass flow (temperature and
pressure automatically compensated as per the
thermal mass flow principle), and therefore much
more precision for the volumetric approaches. In
addition to the improved accuracy particularly
during pressure or temperature changes these
meters allow users to remotely monitor the process and can also control with an optional on-off
valve. Further, the user can program the meter so
that the data can be stored in the memory inside
the meter head for data download and analysis. The meters also
provide a user-defined password for data safety.
TVA (Target-Variable Area) Steam Flowmeter

Spirax Sarcos TVA (Target-Variable Area) flowmeter is a multivariable saturated steam meter with minimal straight-run
requirements and has a 50-to-1 turndown. The meter features
built-in density compensation for accurate mass flow measurement. It needs only six upstream and three downstream pipe
diameters of straight piping, making it suitable for installation in
confined spaces. The wafer is designed to provide lightweight,
easy installation. Critical measuring surfaces are resistant to
erosion by water droplets present in saturated steam, ensuring that accurate measurement is maintained over a long
period. No accessories or flow computers are required.
Integral keypad/display for easy setup and indication of
flowrate, total flow, pressure, temperature, and power.

The TVA incorporates an innovative moving cone design,
which not only provides exceptional flow range capability;
but it reshapes the flow profile to allow installation with
short pipe runs. The cones large surface area disperses the
high impact energy of wet steam, making it very resistant to
erosion and reliable in the long term.
One application where the TVA is a particularly good fit is
for universities that have widely variable flowrates between
high winter and low summer steam loads. The TVA is
capable of measuring these wide ranges in flow accurately with no modifications or required maintenance.
Hot-Tap Dual-Technology Flowmeter

Veriss Hot Tap Accelabar flowmeter is designed to
allow easy retraction of the flow-sensing element
located in the throat of the Accelabar nozzle without shutting down or depressurizing the pipeline.
Its retractable drive rod assembly allows for quick
inspection of the sensor in dirty fluids or where
periodic inspection is required.
The Hot Tap Accelabar Sensor allows the nozzle
and flanges to stay in place while the sensor portion is inspected. Prior to its invention, in order for
the sensor portion of the Accelabar to be removed
for inspection or maintenance, the process would have to be shut
down and the pipe depressurized. Bringing a line out of service to
inspect a sensor is very costly and time consuming.
The Hot Tap Accelabar allows for sensor inspection over any range of flows and operating conditions at 600# ANSI (1,440 PSI @ 100 F or 850 F
max) or below.
Testimonial: The Hot Tap Accelebar has provided more reliable measurement due to its high
turndown capability with the added benefit of
retracting and inspecting the sensor for periodic
buildup common in our process environment. Prior
to installation of the Hot Tap Accelebar, we used
orifice plates that did not give us the necessary turndown and
they cost us two days of shutdown time for inspection and maintenance. Ops supervisor for oil & natural gas producer.

FC-0611-FA.1.indd 27
June 2011 27
6/15/11 1:20 PM
CONTROL
Air-Operated, Double-Diaphragm Pumps for Semicon Applications
ALMATECs FUTUR OMEGA-Series is a line of
air-operated double-diaphragm pumps designed
for high-end semiconductor applications. The
line features a patented cascade sealing system
and a patented air-control system for lubrication-free and maintenance-free operation.
Using PTFE or stainless steel for all outside
housing parts and nonwetted parts, safety is
improved because the pumps are resistant
to acid mists and acid leaking. The optimized
PTFE material of the diaphragm has a doubledstrength against flexural stress compared to
standard PTFE, helping to reduce maintenance
and production costs.
Solid housing parts are machined on modern CNC-machines, which enable the smallest
possible tolerances. The solid housings absorb
mechanical vibrations and noise level much better than thin-walled housings.
Mass Flow Controller Resistant to Pressure & Temperature Fluctuations

Brooks Instruments GF Series mass flow controller is a highly modular, user-programmable,
metal-sealed device based on Brooks expertise in
pressure transient insensitive (PTI) technology that
is designed to minimize process gas flow variation
due to pressure and temperature fluctuations.
At the heart of the GF Series is Brooks MultiFlo,
a patented technology that allows users to select
new gas calibrations and full-scale ranges without
the trouble and cost of removing the mass flow
controller from the gas line. A major advancement over traditional
single-point gas conversion factors, MultiFlo mass flow controllers
typically deliver a three times improvement in accuracy through
advanced gas modeling and compensation for non-ideal/non-linear
gases. Selecting a new gas automatically establishes optimized
PID settings for dynamic gas control, compensating for the effects
of gas density and ensuring smooth overshoot-free transition
between flowrates with steady-state stability. The GF Series fourth-
generation MultiFlo technology continues to lead

the market with the most accurate and most rangeable performance through extensive refinement and
physical validation on critical process gases.
In 2010, Brooks increased the range of flowrates available on the GF Series from 3 SCCM to
30 SLPM to a new full-scale flowrate of 55 SLPM.
The GF Series is offered with a 300 ms flow
setting time (GF125) and one-second response
(GF100/120). For applications requiring a slower
flow response, a user-programmable ramp function linearly transitions the flow between set points over a period of up to one hour
with a resolution of 2 ms.
The GF125 enables users to simplify and reduce the size and
cost of gas panels by eliminating the need for point-of-use pressure regulators, pressure transducers, and associated hardware.
Additionally, the all-metal flow path ensures compatibility with
all gas media.
Advanced Control Head for Linear Process Valves

Burkerts Type 8691 control head is optimized for integrated mounting on linear process valves. The device
features bright light LED visual feedback, universal
1/4 & 6mm tube connection, built-in cleanable air
filter, positive air pressure electronics housing, washdown environment optimization, and automatic switch
position adjustment. An optional integrated pilot
valve controls single or double-acting actuators.
As an option, a fieldbus interface (AS-Interface or
DeviceNet) can be chosen. The calibration of the
valve end position is accomplished through a contactfree analog position sensor, which automatically recognizes and
saves the valve end position through the Teach function when
starting up. The device is designed to provide enhanced

startup and validation time with automatic switch setting both for initial system startup and after maintenance on the underlying valves. Not subject to variation
in target positions due to plant inferences.
Testimonial: The Type 8691 is ideal to retrofit any
kind of piston operated pneumatic actuator. It is
sturdy built and absolutely water and air tight. The
Type 8691 can be setup to prevent environmental
air intake with efficient installation, especially via ASI
Fieldbus at an affordable price. A leading systems integrator,
who has worked with the Type 8691.

28 June 2011
Flow Control
Wireless Position Monitor & Limit Switch

Emerson Process Managements Fisher 4320 wireless position monitor is a noncontacting and linkage-less wireless position
transmitter and limit switch. It is a rugged measurement device that
provides a precise wireless feedback signal to indicate equipment
position with a percent of span plus on/off indication. The 4320 can
be used to monitor equipment, such as valves or anything else that
has a rotary or linear movement. The wireless position monitor periodically reads the position of a measured device and transmits that
data over the wireless network.
The 4320 wireless position monitor is battery-powered,

eliminating the need to install wires. A recently added
option enables the use of external DC power. These
power options make it easier to design new applications
or implement into retrofit locations. Instrument calibra
calibration and commissioning is performed with a push-but
push-button and liquid crystal display (LCD) interface. The interface
is protected from the environment within a sealed enclo
enclosure and supports multiple languages for ease of use.
Acoustic Switch for Indication & Control

Hawk Measurements Gladiator Acoustic Switch uses acoustic wave technology in a new sender/receiver form for blocked
chute protection, point-level detection, and anti-collision for heavy
machinery. The Gladiator Amplifier powers two AW Transducers,
which use special Hawk-developed software in which both
units pulse and receive each others acoustic echoes. When the
path between the transducers is blocked, the units immediately
detect the presence/absence change of the return signal and trigger a communications relay for indication or control purposes.
The transducers work either together or

independently to detect pulse interference,
allowing twice the application security.
Hawks transducers do not require contact
with the product. The switch requires a
simple one-minute setup and allows for remote test function.
The acoustic switch supports continuous operation in dusty, wet
environments where other technologies fail. The transducers are
used for blocked-chute detection in wet or dry environments.
SPEC IT AND
FORGET IT.
Check-All Valve is your
one-stop supplier for the
check valves you need in the
materials you require. Better
yet, every valve includes the
experience, engineering, and
application know-how you need
for spec-it-and-forget-itreliability.
After all, you have better things to
do, and check valves are all we do.
Call us at 515-224-2301 or
e-mail us at sales@checkall.com.
www.checkall.com
Since 1958
West Des Moines, Iowa, USA
June 2011 29
Smart Conveying Technology for Pump Maintenance

seepexs Smart Conveying Technology (SCT)
is designed to enable more efficient pump
maintenance by making it easier to assemble and dismantle the pumps.
SCT is the next logical development after
seepexs Smart Stator Technology. By separating the stator into two halves, seepex has
optimized pumping technology. Since it was
launched, the globally patentpending innovation has been successfully installed in thousands of pump
installations. Now, with the SCT technology, it is also possible to replace
the rotor in just a few easy steps.
Progressive-cavity pumps with SCT no
longer have to be removed from the instal-
FORCEmeter
Designed For Force
lation for maintenance. Dismantling

and reassembly of piping
and the removal of other
equipment components are
eliminated. Due to the integrated retensioning device, a simple
readjustment of the stator increases the
service life of stator and rotor.
Testimonial: Upgrading to SST has
shown real benefit to the process here at
Wargrave. A complete rebuild has been
replaced with a simple adjustment to
restore flow and we have also been able to
de-rag and de-ice frozen pumps in a matter of minutes. Simon Mattin, Regional
Maintenance Manager, Thames Valley East,
United Kingdom

Mass Flow Controller for HighPressure Gas Applications
Measuring ow made easy

with ForceMeter Technology
www.forcemeter.com
30 June 2011
Sierra Instruments
Smart Trak 2 highpressure controller
features a patented, inherently
linear Laminar Flow
Element (LFE) design,
advanced platinum
sensor technology,
and a patent-pending notched valve specifically designed for high-pressure applications. The device can control flow over
ranges from 5,000 PSIG in to 0 PSIG out
to 5,000 PSIG in and 4,990 PSIG out.
The unit is available with a Pilot Module,
which is a front-mounted or hand-held
control device that allows users to employ
Sierras Dial-A-Gas technology to change
flowrate, modify engineering units, or
reconfigure the instrument. With the Pilot
Module, the user can set zero, span, and
full scale for each of 10 different gases.
With the addition of Sierras Compod
technology, the Smart Trak 2 transforms
into a network-enabled MODBUS RTU with
programmable relays and analog inputs.

Flow Control
Energy Saving Technology for Air-Operated Double-Diaphragm Pumps

AODD pumps with Warren Rupps
AirVantage Energy Saving Technology are
equipped with a microprocessor that is
adaptive and continuously
manages the amount
of air volume required
to operate the pump at
desired flowrates.
This adaptive technology determines the
optimal diaphragm rod
velocity and relays the
information to an air-
distribution valve at the air inlet location of

the pump. The valve acts as a gated air management system, allowing only enough air to
enter each inner-pump chamber. Diaphragms
perform at their optimal operating point, with
less air consumption. As the pump experiences air inlet fluctuations or other changes that
affect air flow, the system adapts to optimize
the pumps performance.

Testimonial: [Over a 30-day] period of time,
AirVantage reduced our air consumption by
23 percent while maintaining our desired
flow rates. Rick Klok, Plant Manager,
Grains and Powders Manufacturing Facility,
Saint Gobain

Diaphragm Valve Actuator

With Easy-to-Change
Power Unit
Top Line Process
Equipment Companys
E-360 Diaphragm Valve
Actuator is designed so
that the actuator power
unit can be easily maintained and the
functions of the unit can be changed
without exposing the product process to
atmosphere. Thus, the device eliminates
product contamination and reduces product loss, delays and costs incurred restarting the system and/or system revalidation.
Key features of the device include:
Air inlets are on a 360-degree swivel ring
Bright yellow 360-degree visual indicator
Black Polyamide power unit (stainless
steel optional)
Stainless bases for all valve configurations
Power unit can be either normally
closed, normally open, or double-acting
Each power unit is head-rated for use
with either Teflon-faced or elastomertype diaphragms
Stainless bases will accommodate
either bayonet or threaded-style diaphragms
Standard North American connections
NPT
Specifically designed to meet
cGMP manufacturing practices

June 2011 31
CONTAINMENT
Hybrid Connector for Fluid, Air & Electrical Lines
Colder Products Hybrid Connector combines
fluid, air and electrical lines in one easy-to-use
connection. Integrating these connections allows
clinicians and users to make a single, simple
and secure connection between hand pieces
and equipment, eliminating multiple connection
points and potential misconnections.
The Hybrid Connector includes a panel-mounted female socket for use in the device or equipment and an integral hose coupling that comes
complete with an eight-inch umbilical hose, containing all wiring
and fluid tubing. The fluid couplers are made from glass-filled
polypropylene with stainless steel valve springs and EPDM o-rings.
The external parts, such as housings and rotating collar, are also
polypropylene. The hose coupling has an acetal collar that secures
the tubing to the coupler. Finally, the external umbilical tubing is
flexible and re-enforced PVC with PVC fluid tubes routed through
the umbilical. Operating temperatures range from

40 F (4 C) to 100 F (38 C). Pressure ranges from
vacuum to 45 PSI (3.1 bar).
The vast majority of the medical equipment
available today has fluid, air and electrical connections carefully separated. However, so many
different connections on a machine or device
can be confusing for clinicians and end-users,
leading to potentially fatal consequences. The
innovative dry break valved fluid connectors
in the Hybrid Connector have no spillage or inclusion upon disconnection, allowing fluid lines in the connector to be in close
proximity to the multiple electrical contacts. Multiple connections
can be made with one simple motion that is easy and intuitive for
clinicians and end-users alike.
In addition, design engineers can now directly integrate hand
pieces and equipment, streamlining and simplifying their product.
Low-Friction Hose to Eliminate Hose-Routing Problems

Kuriyama of Americas
s Piranhaflex Plus 100R7
Hydraulic Hose provides a special lowfriction cover to eliminate hose-routing
problems between hose sheaves and pulleys
when used in Fork Truck hydraulic applications.
Although the Piranhaflex Plus hose provides similar PSI characteristics to other hydraulic hoses in the marketplace; its unique,
specially engineered low-friction polyurethane cover compound
makes it easier to rout the hoses when bundled in fork truck
applications. This important characteristic, along with increased
flexibility, helps to extend hose service life with less frequent
replacement of hoses required.

Use of Piranhaflex Plus hoses
in a fork truck application elimi
eliminates hose-sticking problems and premature cover wear due
to chafing, which requires replacement hoses to be used more
frequently.
Even though Piranhaflex Plus hydraulic hose is still a relatively
new product in the field, similar uses of this special Piranhamade cover, used in the sewer and jetting hose industries, have
already shown to provide increased wear characteristics in very
tough application environments.
PTFE-Based Sealing Material for Extreme Applications

Trelleborg Sealing Solutions Turcon M12 is
a polytetrafluoroethylene (PTFE)-based sealing
material provides key hydraulic sealing characteristics, such as friction, wear, and highpressure operation.
Testing has shown that Turcon M12 is resistant to virtually all media, including a broad
range of lubricants, and has outstanding wearresistance and friction characteristics. The cost-effective material
also provides customers with extended seal life, as well as a wide
operating window in terms of temperature, pressure and velocity
Key to achieving maximum seal life is to make sure that sealing compounds match up to application parameters. If a material
can stand up to a greater variety of conditions,

this makes the compound more versatile.
Considerable R&D time was devoted to
develop a PTFE-based material that is compatible with a broad range of lubricants. It also
had to demonstrate minimal wear with excellent friction characteristics at extreme temperatures, high pressures, and rapid velocities.
A specification was put together for a dream PTFE material,
one that could fit virtually all hydraulic applications. This, according to Trelleborg, was achieved this with Turcon M12, enabling
the customers products to meet a more universal range of sealing applications.

32 June 2011
Flow Control
FlowControl_6-11_IO2405.qxd:Full Page
5/26/11
4:09 PM
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2011 McCrometer, Inc.
flow update
By Jesse Yoder, Ph.D. & Belinda Burum
Ge F. Fischer Tells It His Way
Reflections From a Pioneer of Flow Measurement
hile at Gastech 2011 in

Amsterdam, Flow Research interviewed Ge F. Fischer, founder
of the Instromet Group, for its interview
series, Pioneers of Instrumentation. The
story of Instromet is a fascinating one that
involves several flow companies, including
Ruhrgas, E.On, American Meter, and Elster.
Today, Instromet has been absorbed by
Elster and is part of the Elster Gas North
America and Gas International business
units. The Elster-Instromet group is a leading supplier of ultrasonic and turbine flowmeters. In 2009, the company introduced
a bi-directional turbine meter designed to
significantly reduce pressure drop while
providing a flow capacity matching existing ultrasonic gas meters. The company
also has developed a gas metering solution that is designed to reduce measurement uncertainty by combining turbine and
ultrasonic meters in a serial solution.
Measuring Gas As a Hobby
Im a hobbyist of gas measurement,

says Ge F. Fischer. Even my wife says
the only thing that interests me is gas.
Fischer spent 30 years as a key figure at
Instromet and built the company into the
Instromet Group, one of the largest and
most influential flowmeter manufacturers
in the world. Fischer is now semi-retired,
but he continues his love for turbine flowmeters and his distaste for bean counters who hamper technology development
with their incessant focus on short-term
business results.
When Fischer sold Instromet 10 years
ago, he started investigating a system for
continuous online checking of specific
turbine meters to eliminate the cumbersome need to pull a meter offline except
when there is a negative indication. Today,
he is still passionate about the need for
easier methods of calibration and says
he is about to come out with something
new involving turbine meters as in-line
verification of calibration values. His son,
Roger Fischer, works with Elster Amco de
Sudamerica in Latin America, promoting
the Instromet product line.
Rockwell-izing the
Turbine Meter
Ge F. Fischer, founder of the Instromet Group,

has enjoyed a long and storied career in the
flow measurement business, and he still may
have a trick or two up his sleeve.
34 June 2011
Fischers career started as an engineer

in the Royal Dutch Navy. In 1968, he
began honing his range of professional
skills in his first non-military position at
Rockwell Manufacturing (now Rockwell
International). Over the years, Rockwell
gave Fischer a range of business experiences, as well as training in the U.S.,
including a stint at Harvard University.
Being in European Rockwell, one time you
had to be an engineer or salesman, another time the bookkeeper, explains Fischer.
Rockwell started Fischer off in the
Rotterdam and Brussels facilities. Fischer
set up a plant for Rockwell in Essen,
Belgium, that still stands today as an
Elster-Instromet facility.
Rockwell was investigating gas production, sales, and marketing in The

Netherlands and Europe after some gas
finds a few years earlier in the North
Sea near Groningen, The Netherlands.
As a result of the gas finds, American
Meter also developed a presence in The
Netherlands.
At that time, Rockwells facility in
Belgium was designing and constructing
skid-mounted measurement and control
stations for the European gas industry.
One of its main customers was Gasunie,
a Dutch natural gas infrastructure and
transportation company operating in
The Netherlands and Germany. Gasunie
was using turbine meters, and at some
point had a need for thousands of them.
Instromet, which was founded in 1965,
had the capability to produce these
meters, so they earned the business and
started building them.
Meanwhile, the owners of Instromet
had a dispute and decided to offer the
company for sale in 1971. Rockwell asked
Fischer to buy the company.
As I had set up a plant for Rockwell
in Belgium, they instructed me to go and
have a look, says Fischer. Then, when
they bought it, they said, the distance is
only 2.5 hours by car, why dont you do
this as well. So they put me in charge of
the Instromet operation. On April 26, 1971,
they said, Here, Fischer, you have your
little toy. And they flew back to Pittsburgh.
At that time, the world wasnt run by
the bookkeepers yet. It was not run by the
bean counters. So now I had the Belgium
plant and a Dutch plant in Silvolde. I split
my time between them on a weekly basis.
We Rockwellized the technology of the
turbine meter, and we became, suddenly,
the number one turbine meter in the world.
The available European gas turbine
meters were not designed for elevated gas
pressures, and therefore lacked the accuracy customers were seeking. Rockwell modernized the turbine meter by stabilizing the
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flow update
measurement curve at elevated pressures.

Rockwells turbine meter made it
possible to measure gas under elevated
pressures and at a far advanced accuracy
range, says Fischer. Today everyone is
making copies of those old turbine meters.
Rockwell Chooses B1 Bomber

Over Turbine Meters
In the mid 1970s, Rockwells focus shifted,

which was part of the reason it ended up
selling its turbine meter business to Fischer.
Rockwell had a defense contract for
the B1 bomber, so nobody in Pittsburgh
was really interested in a $5 million product when they had a $5 billion product,
Fischer explains. They made me an offer
I couldnt refuse, I became a minority
shareholder in the European Instromet,
and Rockwell departed.
I started with Rockwell when everybody
was driving cars. Then they were in the
military and space businesses, and there
werent any more cars left in Pittsburgh.
Everybody was riding in helicopters to the
various manufacturing plants.
Fischer had two backers, banking
shareholders who, he says, had just
bought an airplane at 40,000 feet and
didnt know how to fly the plane, and an
outspoken interest serving as a second
guarantee from customer Gasunie.
After a year, one of the shareholders
wanted out. Fischer and the other partner
divided the shares. About six years later,
that remaining partner suffered a seizure
that left him paralyzed on one side, and he
agreed to sell his majority shares to Fischer.
The funny part was, Rockwell wanted
to buy the company back again because
things had changed, says Fischer. I was
handicapped because they were offering real
money, and I had to meet their offer. Anyway,
that was all said and done, and I became the
single majority owner of the group.
Pitching Turbine Meters to the

Bean Counters
One of Fischers jobs as the new sole

owner of Instromet in the early to mid
1980s was to move the mentality of major
gas companies from orifice plates to turbine meters to measure large volumes of
gas. Ironically, it was Fischers strategy of
aiming his pitch at the bean counters that
36 June 2011
contributed to his early success.

Gas companies are very conservative
and dont like to change anything unless
you can convince them its a good move
financially, says Fischer. They were holding on to the orifice meters. Thats what
they learned. I always requested to talk to
the CFIO, he says. Id ask, How good are
your financial figures? Can we go over the
details? How good is your accuracy? Are
you plus or minus 0.1 or 0.5? Because,
honestly, 0.5 accuracy, when youre talking
about couple of million dollars [of product],
is a lot of money. The turbine meters accuracy cant be beat youll see for yourself.
ed, We would like to, but we dont have

the ideas.
Ruhrgas ended up buying Instromet in
2001 and internally transferred the essence
to Elster. Then E.ON acquired Ruhrgas.
At the time, Ruhrgas was doing about
16 billion and E.ON was doing42 billion.
Part of E.ON was Elster, which was doing
1.3-1.5 billion, says Fischer.
Fischer says E.ON was unsure of what
to do with Elster and ultimately sold it to
CVC Capital Partners. In 2005, CVC Capital
Partners acquired Ruhrgas Industries and
renamed it the Elster Group.
Adding Ultrasonic to the Mix
Turbine meters are still a new technology, says Fischer. Turbine meters have
built-in precision and the capability to
remain accurate even with flow disturbance.
Ultrasonic meters are excellent, except
you may not know what will deform the
flow you cant correct for that. You
can do the straightening thing [provide a
straight run] but once you do that, youre
back to a turbine meter configuration.
Ultrasonic meters become of interest
specifically in larger pipelines where there
is no flow perturbation. If you have any
flow disturbance up front of the meter, then
you really dont know whats going to hit
your ultrasonic meter, and you cant completely neutralize or stop that influence.
In order to be sure of the accuracy
of an ultrasonic meter, you really have
to calibrate the meter together with the
upstream and downstream pipeline. Now
you have pipelines you have to transport
to TCC or Euroloop system, which are
almost their own Bible, and cost becomes
a handicap.
When turbine and ultrasonic flowmeters
need to be calibrated, they are often taken
out of service and shipped to a calibration
facility. Shipping can be costly, especially if
the meter is in a remote country or region.
TCC and Euroloop are two such calibration facilities. TCC is located in Manitoba,
Canada, and was founded in 1999. It has
provided ultrasonic and turbine calibration services since 2001. Euroloop is a
new flow calibration facility located in
Rotterdam, the Netherlands. It provides
calibration facilities for both oil and gas
flowmeters. Euroloop was established
Later, Instromet bought an ultrasonic flowmeter line from Stork, a company located
in Dordrecht, The Netherlands.
Stork had been developing an ultrasonic meter for many years but never had
the reputation, so I bought it from them,
explains Fischer. They had done a good
job technically, but the owner wasnt willing to commit sufficient effort. Marketing,
developing a reputation, and seeking
metrological approvals is expensive. Stork
decided it wasnt in their interest to keep
the ultrasonic meter.
Around that time, Instromet also
obtained one of the biggest measurement contracts in Russia $100 million.
Instromet also became a 25 percent
shareholder in TransCanada Calibrations
Ltd. (TCC), not with cash, but with the
promise to deliver ultrasonic and turbine
flowmeters to serve as calibration instruments in the laboratory. TCC, located on
the TransCanada Pipeline mainline, today
provides turbine and ultrasonic meter
repair and refurbishing, high-pressure natural gas flow calibration, and pressure and
temperature device calibration services to
an international customer base.
The End of an Era
Around 1998, Fischer was approached by

Ruhrgas, owner of AMCO and Elster. The
company started talking about the possibility of acquiring the Instromet group.
First, I started laughing about it, says
Fischer. I said, Why dont you invest
10-15 million DM and get yourself up the
line? To this, Fischer says they respond-
Turbine Meters Still Shine
Flow Control
by the Van Swinden Laboratorium (VSL),

which was formerly National Metrology
Institute (NMi). It was built with the cooperation of a number of leading flowmeter
companies, including KROHNE, Elster
Instromet, and Endress+Hauser. Euroloop
began operations in March 2010.
A Legacy Continues
You know, when Rockwell sold out 40

years ago, they offered me a job in the
States, says Fischer. I liked the money,
but they were going to send me to
Anaheim, and its a financially oriented
company. If someone says can I interest you in something else? My answer is
Maybe. But I know what Im doing in gas
measurement, because thats where Ive
devoted my time and my interest.
Today, the Elster Group is one of the
worlds largest electricity, gas, and water
measurement and control providers. Its
offerings include distribution monitoring
and control, advanced smart metering,
demand response, networking and soft-
ware solutions, and numerous related

communications and services.
Elster has one of the most extensive
installed revenue measurement bases
in the world, with more than 200 million
metering devices deployed over the course
of the last 10 years. It sells its products
and services in more than 130 countries
across electricity, gas, water, and multiutility applications for residential, commercial and industrial, and transmission and
distribution applications.
Elster Group operates production facilities in Belgium, Denmark, Netherlands,
France, Germany, Spain, Italy, United
Kingdom, Turkey, Poland, Russia, Slovakia,
China, England, Canada, Mexico, Argentina,
and the United States. FC
Jesse Yoder, Ph.D., is president of Flow
Research Inc. in Wakefield, Mass., a company he founded in 1998. He has 23 years
of experience as an analyst and writer
in process control. Yoder specializes in
flowmeters and other field devices, includ-
ing pressure and temperature

products. He has written over 120 journal
articles on instrumentation topics. Dr.
Yoder can be reached at jesse@flowresearch.com.
Belinda Burum, editor and writer, has

worked in high-tech for 20 years as a
technical marketing writer, marketing
communications manager, and customer
references consultant. She joined Flow
Research in 2002, assisting in the development of market studies and serving
as editor of Flow Researchs Energy
Monitor and Market Barometer quarterly reports. She can be reached at belinda@flowre search.com or 781 245-3200.
www.flowresearch.com
In the July issue of Flow Control
magazine, Flow Research will follow
up this article with a detailed analysis
of the tubine flowmeter market and the
technology trends in this category.
June 2011 37
fluid handling 101
By Zoran Savovic
Flow Problems Solved
Forum Selections from PipeFlowCalculations.com

The following Q&As are based on recent forum entries at
PipeFlowCalculations.com, a website featuring calculators and a
bulletin board for fluid flow applications.
A: It would only be 257 FPS if pressure is at standard conditions

at 1.013 bar, but since the pressure is 90 PSI (cca 6 bar), it is
about six times less (257/6 = 44 FPS - approx.)
Defining Maximum Gas Pipe Velocity
Q: So its acceptable to have a 20,000 CFH gas flow in a

two-inch pipe with 90 PSI with a drop of 10 PSI? (yielding
~14m/s pipe velocity)?
A: For underground installations, 20 m/s is normal. Maximum

velocity in a pipeline, on the other hand, is defined by available
pressure, but in control and safety valves, it can be allowed up to
100 m/s.
A: Yes, it is just about perfect.
Q: What is the typical natural gas pipe velocity, and what is

the maximum gas pipe velocity?
Q: Thanks for the information. I noticed from the calculator

on PipeFlowCalculations.com that for two-inch pipe with
1,500 feet length, 90 PSI in and 10 PSI drop, it gives a result
of 337 CFM gas flow with a 44 FPS and 50 FPS velocity.
Shouldnt the velocity of this be 257 FPS (based on that 337
CFM flow and two-inch pipe).
How to Calculate Gas Consumption
Q: We have a batch fryer in our food processing plant. There

is a gas flowmeter to record the flow of gas. We use LPG that
is stored in a sphere, underground. The gas supplier bills us
for LPG in MT (assume in liquid form). How do I calculate
consumption and cost of the LPG per pound of cashews/nuts
roasted. The flowmeter readings in cubic M/hr are recorded
at the start of fryer and after shut down of fryer, during
which time X pounds of nuts would have been roasted.
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10 to 2,000 H2O differential ranges available for clean, dry gases
1 PSID to 500 PSID differential isolated pressure sensors for liquid media on orifice
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-15/15 PSIG to -15/3000 PSIG and 17 PSIA to 100 PSIA models
Two SPST opto switches
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38 June 2011
Flow Control
fluid handling 101
Obviously, we have to trace the consumption in vapor form to

liquid form, to find out the costs.
A: First you need to know if the flowrate of the gas mixture is
measured on real conditions with some pressure that is above
atmospheric. Or is it already converted to standard conditions
with volume corrector? If the flowrate that is measured is already
converted to standard condition, calculation of mass flowrate is
straight-forward. You must know the composition of the mixture
-- propane butane ratio -- like 30-70 percent or so. Then the
density of that mixture can be calculated based on the density of
every single component and its participation in mixture.
For the theory on how to calculate fluid mixture density, see:
http://flwctrl.com/iF932N
Component density should be used on standard conditions,
and you can view the table for it at:
http://flwctrl.com/l0Ni0e
When you have the fluid-mixture density, then the measured
flowrate should be multiplied with the density to determine
weight flowrate:
decrease. Can you explain if Im wrong, or not?

A: It may seem incorrect, but if you look at the equation for
flowrate through an orifice, you can see that only in terms of
discharge coefficient C, through Reynolds number, viscosity is
treated. Also, in the equation for discharge coefficient, Reynolds
number is in the denominator, which means if viscosity is higher,
Reynolds number is lower, and the coefficient of discharge is also
higher, which results in higher flowrate for the same pressure difference in front of and after the orifice.
That is a mathematical solution and confirmation for this problem, but what about the physical? I would say that due to higher
viscosity, the vena contracta effect is smaller, and the contraction
of flow stream after the orifice is not as big as it is with a less
viscous fluid. As contraction of the flow stream after the orifice is
smaller, the flow cross section is bigger and, correspondingly, the
flowrate is also higher.
To review the theory from ISO for orifice flow, see:
http://flwctrl.com/jyqIci FC
Zoran Savovic is a mechanical engineer with more than 10 years
of experience in fluid transport systems design and engineering.
He is also the owner and editor of pipeflowcalculations.com.
G=Q x rho
where:
G = weight flowrate -- which is the same for gas and liquid
Q = measured flowrate - volume
rho = mixture density
If the measured gas flowrate is not converted to standard conditions, then the
density of every single component should
be used on the pressure and temperature
that is on the point of flowrate measurement. This means you should use component density on standard conditions using
the gas state equation. Calculate density
on a given pressure.
p1/rho1=RT1
p1/p2 * rho2/rho1 = T1/T2
if 1 is for standard conditions then
rho2 = rho1 * T1/T2 * p2/p1
www.pipeflowcalculations.com
Max Flow Meters
If you measure very little,

you need us a lot
Tiny flow rates and small dosages
can be measured! Don't change
your process, change your meter.
Relationship Between
Reynolds Number
& Flow Through an Orifice
Q: Hi, I was wondering about your software -- I was looking for something
like it for years gone by, but it looks
wrong that in changing the viscosity of the fluid from a light oil to a
thicker one, like from 10 to 100 cSt
(or mm^2/S) the flowing liters passing by the orifice increases instead to
Flow measurement you can count on

Max Machinery Inc.
an ISO9001:2008 certified company
maxmachinery.com
T 707.433.2662
June 2011 39
the pump guy
By Larry Bachus
Observation & Deduction
An Intuitive Investigator Finds a Solution to a Pressing Pump Problem
he greatest detective in literary history asserted that observation and deduction were a science that could be
developed and exercised to remarkable heights. In
The Greek Interpreter, Sherlock Holmes and his brother
Mycroft (another private-eye, though retired)
astound Dr. Watson (Holmes assistant) with a
superb demonstration of observation and deduction while
they sit comfortably in a
London pub.
Mycroft spoke first.
This is an excellent place
to study mankind. Consider
the short, tanned fellow with
his hat pushed back, carrying several
packages. Hes coming towards us now. Sherlock,
Mycroft and Dr. Watson peered into the street through the
window at their booth.
FlowResearch_0710:Layout
1 Sherlock.
5/27/11 And
11:07
AM disPage
An old soldier, I perceive, said
recently
charged from service, remarked Mycroft.
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Id say he served in India as a non-commissioned officer. Royal Artillery, I fancy, said

Sherlock. And a widower, with a child.
added Mycroft.
Children, my dear boy, children,
said Sherlock. Seeing Dr. Watson gaping with astonishment, the two detectives
explained.
Surely, said Sherlock, its not hard
to say that a man with that bearing,
expression of authority, and sunbaked
skin is a soldier more than a private and is not long from India.
You see, India is the only sunny
place where England currently
stations troops.
Mycroft added, Its obvious the man is
recently discharged from the service. He still wears his
ammunition boots. He doesnt have the stride of a cavalry
officer. Yet, he wears his hat on one side, as is shown by
the lighter skin on that side of his brow. He is in the artillery.
His weight doesnt support work as a trench soldier.
Sherlock continued the observation. Then, of course, his complete mourning shows that he has lost someone very dear. The
fact that he is doing his own shopping looks as though it were his
wife who died. He has been buying things for children, I perceive.
There is a rattle. One of the children is very young. His wife may
have died in childbirth. The fact that he has a picture book under
his arm shows that there is another older child to be thought of.
Amazing? For sure! Impossible? No! Especially when you consider that this piece of observation and deduction was actually
performed by Dr. Joseph Bell, a professor of surgery at Edinburgh
University in Scotland. Dr. Bell inspired Arthur Conan Doyle to create the fictional detective Sherlock Holmes.
These preceding paragraphs illustrate my work as a pump
consultant. (I dont just teach pump courses.) The Pump Guy
observes and deduces, aided with over 40 years of experience as
an industrial maintenance practitioner.
Recently, I had the occasion to address some problematic
pumps at an ethanol processing plant in the upper Midwest. I
recalled reading Sherlock Holmes. And while my performance
did, by no stretch of the imagination, approach the heights that
only the inimitable private eye could attain, it was, nonetheless,
rewarding. Beginners luck, I presume.
Joe F., a supervisor at the ethanol plant, met me at the luggage
carousel in the Minneapolis airport. We loaded my stuff into a company pick-up and started a two-hour trek into northern Iowa.
Joe dodged the potholes with his left hand. His right hand was
busy shuffling two plastic cups. A diet soda was in one cup. The
40
June 2011
Flow Control
got pump
problems?
For my line of work,

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has ever spent for
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GET ANSWERS AT THE
Attendee comment,
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December 6-8
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As a controls engineer by
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been a great learning
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Attendee comment,
Houston 2011
I thought this seminar was one

of the best I've attended in my
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systems that we seem to be
working on too much.
Attendee comment, Houston 2010
For more information and to register, please

e-mail Matt@GrandViewMedia.com or call 610.828.1711.
the pump guy
other cup held Joes tobacco-chewing

spit. Both cups bounced and wobbled in
the two console cup holders. I was worried Joe might drink from the wrong cup.
I moved my computer bag away from
splash range.
Joe signed me in at the guard shack.
The afternoon guard bummed a wad off
Joe and the two of them talked and spit
as I watched the safety video. Then we
went to Joes office to talk.
Joe said they were beset with mechanical seal failures on five sister pumps. They
had installed 16 cartridge seals on five
excessive vibration. I allowed the

information to sink in.
As the three of us ruminated (mine was
mental), something clicked in my mind
as I recalled Sherlock and The Greek
Interpreter. It was time to visit the five
sister water pumps. As we walked through
the plant, Joe pointed 40 yards ahead
in the distance and said, Those are the
pumps over there.
And the fourth pump on the right is the
problem! I commented. Joes chew fell
to the ground leaving a line of wet, brown
drool on his white shirt. Joe stopped walk-
Recently, I had the occasion to address some

problematic pumps at an ethanol processing plant
in the upper Midwest. I recalled reading Sherlock
Holmes. And while my performance did, by no
stretch of the imagination, approach the heights that
only the inimitable private eye could attain, it was,
nonetheless, rewarding. Beginners luck, I presume.
centrifugal pumps in the past year. The
pumps were all ANSI spec, same model
and brand, moving industrial water with
the same suction and discharge pipe
diameters. They were not parallel pumps
because the discharge pipes went in different directions, as the plant was built
eight years ago.
Probing a bit, I learned that only one
pump was eating seals. The seals on the
other four pumps had run for over a year
with no leakage. But one pump had eaten
12 cartridge seals in the last year. That
accounted for the 16 seals.
It was pretty clear to me that this was a
pump problem, especially since the pumps
were identical and all of them handled
cold, relatively clean water.
We walked to the maintenance shop
to see the failed seals. Joe offered a wad
to the shop foreman. My suspicion was
reinforced when I observed that all the
failed seals exhibited the same evidence.
Considerable chipping on the outside
diameter of the carbon face suggested
ing and exclaimed, How the _&#@ do

you know that from this distance?
I responded, Though the pumps and
pipes are identical, the motors are not.
That fourth pump has a larger motor. It
suggests one of two motives. Thats either
a two-pole motor (3,500-rpm), or its
larger because the pump is running on the
right extreme of the curve. But, I cant see
that from here. We walked.
Standing over the noisy pumps, I
shouted, The other pumps are running
at 1,750-rpm. This fourth pump is on a
3,500-rpm motor. Its larger than the others, and making more noise.
Joe inserted another wad. With his
attention diverted, I touched the offending
fourth pump with my right hand and the
fifth pump with my left hand. There was a
noticeable difference. Joe tugged my shirt
sleeve and led me away from the noise
toward the shade of a fire-hose shack.
Joe asked, What do you know about a
pump by looking at the electric motor? I
answered, The Affinity Laws state that
42
June 2011
Flow Control
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the pump guy
Page 1
flow changes proportional to the change in

speed. Twice the speed generates twice
the flow. The same laws also state that
power changes by the cube of the change
in the speed. Twice the speed requires
eight times (23) the power to drive the
pump. This fourth motor is larger, probably
for more flow. And this fourth pump and
motor are making all the noise.
Now, any pump or seal manufacturer
will tell you that shaft runout should not
exceed two thousandths of an inch
(0.002) on a mid-frame ANSI pump. That
figure includes a safety factor, because
they know that in the real world, four and
five thousandths runouts are common.
At twice the speed and eight times the
power, this poor pump shaft is experiencing severe runout (maybe 0.040) and
vibrations, which supports the chipped and
broken seal carbons.
I led Joe back to the sister water
pumps. This time we both put our fingertips onto pumps one, two, three and five,
noting the noise, heat and vibrations. A
circle of mechanics and workers (the audi-
ence) had gathered around us.

Then Joe touched the casing of number
four pump. Although pumping the same
cold water, the number four pump was
notably hotter. And, sure enough, the
vibrations were excessive on number four.
And I said so.
An onlooking mechanic raised his
eyebrows and commented that the word
excessive was a relative term. I shot back
that he was absolutely right. The vibrations on pump number four (with the larger
motor) were excessive relative to the level
of vibrations in the other sister pumps.
I stretched my novice luck with another
deduction. This pump eats bearings too!
Joes eyes fixed on the ground, in silence.
He didnt deny it.
We returned to Joes office and sound
insulation. Joe asked, What can we do?
Theres a lot we can do, I said, but not
today. Its already 5:18.
Joe took me to the hotel. The next morning, Joe negotiated potholes with his left
hand for two hours back to the Minneapolis
airport. We scheduled a return visit to the
ethanol plant. As we bounced, the

same two cups of diet soda and stale spit
wobbled in the console cup-holders. Joe
alternately reached for both with his right
hand. I slid my computer bag away from
splash range. True Story! Thanks Sherlock!
It is always possible to find the answer
to a problem if we make a point to doggedly search for it and to constantly
increase our knowledge. Bad Actor pumps
dont exist. Remove these words from your
vocabulary. I wish you all a millionaires
future and a rewarding professional career
with pumps. FC
Larry Bachus, founder of pump services
firm Bachus Company Inc., is a regular
contributor to Flow Control magazine. He
is a pump consultant, lecturer, and inventor based in Nashville, Tenn. Mr. Bachus
is a retired member of ASME and lectures
in both English and Spanish. He can be
reached at larry@bachusinc.com.
www.bachusinc.com
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44
June 2011
Flow Control
Fluid Handling Reference Shelf

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Temperature, Pressure, Flow, & More
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ProcessFlowDirect
www.jazdprocessing.com/processowdirect
Your Source For Fluid Handling Videos
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product information
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product information
www.FlowControlNetwork.com/FreeInfo
June 2011
Connect_1-4page.indd 1
45
5/27/11 10:59 AM
Advertiser Index
Find company Web sites and get free product information online at www.flowcontrolnetwork.com/freeinfo.
BC = Back Cover - IBC = Inside Back Cover - IFC = Inside Front Cover
Page
RS #
Page
RS #
FlowTube
46
30
Pump Guy Seminar
41
25
Flow Research Inc
40
24
Rotork Process Controls
IBC
32
21
FORCEmeter
Venture Measurement
30
18
Sage Metering
31
19
13
GF Piping Systems
IFC
Spitzer and Boyes LLC
44
28
Bachus Company Inc
44
29
GPIMeters.com
15
10
Sponsler Precision
Turbine Flowmeters
19
12
Brooks Instrument
25
16
Harwil Corporation
42
26
Spraying Systems Co
45
200
Burger & Brown

Engineering Smartflow
45
204
Hoffer Flow Controls
Veris Inc
17
11
CheckAll Valve
29
17
John C Ernst Company
24
14
PRODUCT INDEX
Magnetrol International
11
ALMATEC
28
Max Machinery
39
NA
Brooks Instrument
28
McCrometer
33
20
Burkert
28
Meriam Process Technologies 38
23
Cameron
20
Colder Products Company
32
COX Flow Measurement
20
Emerson Process Mgmt Fisher
29
Emerson Process Mgmt

Micro Motion Division
21
Endress+Hauser
21
Fluid Components International
22
Select appropriate issue of Flow Control Magazine.
Flow Line Options Corp
22
Select advertisements that interest you.
Greyline Instruments
22
Enter your email & click Submit Request.
Hawk Measurement
29
INKnet Systems
24
Innovative Sensor Technologies
25
Kuriyama of America
32
McCrometer
26
LJ Star
26
Sage Metering
26
Seepex
30
Siargo
27
Sierra Instrument
30
Spirax Sarco
27
Name
Page
RS #
Alicat Scientific
ASCO Emerson Industrial

Automation
Ashcroft Inc
35
Assured Automation
CME Aerospace
Control Products
45, 48 203, 31
Cole-Parmer
45
201
Collins Instrument Company 37
22
Emerson Process
Management Fisher
43, BC
27, 33
23
13
Endress+Hauser
Flow Control Career Center
Name
Omega Engineering Inc
1, 45
2, 202
Orange Research
10
ProcessFlowDirect
24
15
FREE
PRODUCT INFORMATION ONLINE

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1
2
3
4
Go to: www.flowcontrolnetwork.com/freeinfo
Your Source For Fluid Handling Videos

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sponsor packs, e-mail FlowControl@GrandViewMedia.com.
Name
Page
Top Line Process Equipment Company 31

Trelleborg Sealing Solutions
32
Veris
27
Warren Rupp
31
46 June 2011
Flow Control
think tank
March Winner: Steve Conway
Electrical Engineer, Argus Consulting Inc.
Solve This Word Search

Win a $50 Best Buy Gift Card
One lucky entrant who has solved the puzzle correctly will win a
$50 Best Buy gift card. Best Buy is North Americas leading consumer electronics retailer. You can use your gift card in the store or
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Fax solution to: (205) 408-3799

If there are no completely correct entries, a winner will be
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I would like to receive/continue Flow Control magazine: _____ Yes _____ No.
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GLOSSARY OF TERMS: Pressure Regulators

ACCURACY: The variation in outlet pressure that occurs under steady-state conditions
within the control range of a regulator.
BACK PRESSURE: A back-pressure regulator is designed to keep an inlet pressure
constant and controls this pressure even with varying flow. A back-pressure regulator
can either open, in case of excess pressure, or close when the pressure drops below a
certain level.
BIAS: The pressure increment that is adjusted or preset into a regulator and is usually
held constant during normal functioning (differential pressure).
CAPTURED VENT: A feature incorporated in a self-venting pressure regulator that
provides an additional flow path to permit the piping away of expelled fluids from the
regulators vent valve.
CONTROL: Ability of the regulator to hold a given outlet pressure setpoint.
CRACKING PRESSURE: In back-pressure control, the term used to describe the inlet
pressure to the regulator at which flow starts.
CREEP: Any increase in the outlet pressure subsequent to lock up usually a longterm, slow pressure increase. This indicates a regulator leak and requires service.
DOMELOADING: A method of energizing a pressure regulator using a compressed gas
(usually air or nitrogen) in place of a spring.
DROOP: The outlet pressure change from the set pressure, which occurs as flowrate
increases.
LOCKUP: The outlet pressure increase that occurs above the set pressure as the flow
is decreased to zero.
PILOT REGULATOR: A pressure regulator that feeds gas or hydraulic pressure into the
dome of a dome-loaded regulator. The pilot regulator should be self-venting or provide
a constant bleed reference in order to permit pressure in the dome to be adjusted to a
lower pressure.
POPPET: A sealing mechanism that restricts flow through the orifice between the highand low-pressure regions of the regulator.
PRESSURE REDUCING: A pressure-reducing regulator is designed to reduce pressure
between the inlet and the outlet and control the reduced outlet pressure to a set value.
REGULATOR: A device that controls pressure at a predetermined value or varies it
according to a predetermined plan.
REPEATABILITY: The ability of a regulator to return to the same set pressure subsequent to being subjected to various pressure and flow demands.
ACCURACY
PILOT REGULATOR
BACK PRESSURE
POPPET
RESEAT PRESSURE: The inlet pressure of a back-pressure regulator at which flow stops.
BIAS
PRESSURE REDUCING
CAPTURED VENT
REGULATOR
RESOLUTION: Number of handle turns needed to adjust a regulator from its lowest to
highest outlet pressure setting.
CONTROL
REPEATABILITY
CRACKING PRESSURE
RESEAT PRESSURE
CREEP
RESOLUTION
SET PRESSURE: The desired outlet pressure of a regulator, normally stated at a single
flow condition.
DOMELOADING
SELF VENTING
SPRING LOADING: A method of energizing a regulator using spring force.
DROOP
SET PRESSURE
LOCKUP
SPRING LOADING
SELF VENTING: A feature that enables the unit to vent the outlet pressure when the
knob handle is adjusted in the decrease direction.
The terms and definitions for this issues Word Search were contributed by Swagelok
Company (www.swagelok.com).
June 2011 47
think tank
quiz corner: Measuring Fluid Viscosity
hich of the following common fluids is most viscous?
A. Water
B. Honey
C. Mustard
D. Peanut Butter
E. Cannot Be Determined
Commentary
Viscosity is the ability of a fluid to flow over itself. Viscosity is

dependent upon composition, temperature, and the amount of
stress applied to the fluid.
The composition of water is well-defined, so its viscosity is also
well-defined, likely the lowest among these liquids. The composition of honey, mustard, and peanut butter can vary such that (for
by David W. Spitzer
example) heavier mustard could be more viscous than honey,

while lighter mustard could be less viscous. Peanut butter is
likely more viscous than either honey or mustard. The correct
answer appears to be Answer D.
Additional Complicating Factors
Complicating the above analysis is that temperature also affects

viscosity, whereby increasing temperature generally reduces the
viscosity of the fluid. Therefore, increasing the temperature of
peanut butter will reduce its viscosity. Conversely, decreasing the
temperature of honey will increase its viscosity. Therefore, it is
conceivable that the viscosity of hot peanut butter could be lower
than the viscosity of cold honey.
Without more detailed investigation, Answer E may be the
pragmatic choice. FC
David W. Spitzer is a regular contributor to Flow Control with
more than 35 years of experience in specifying, building, installing, startup, troubleshooting, and teaching process control instrumentation. Mr. Spitzer has written over 10 books and 150 technical articles about instrumentation and process control, including
the popular Consumer Guide series that compares flowmeters
by supplier. Mr. Spitzer is a principal in Spitzer and Boyes LLC,
offering engineering, expert witness, development, marketing,
and distribution consulting for manufacturing and automation
companies. He can be reached at 845 623-1830.
MAY SOLUTION: Water Treatment
48 June 2011
Flow Control
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Reections From a Pioneer of Flow Pump Guy Goes Sherlock Holmes Pipe Flow Problems Solved

JUNE 2011 Vol. XVII, No. 6 www.FlowControlNetwork.com

MASTERING Hot Cutover

2882 Dow Avenue, Tustin, CA 92780-7258

Optional automatic pH compensation

Circle 1 or Request Info Instantly at www.FlowControlNetwork.com

Where Do I Go for Flow, Level, and Environmental Products?

Your single source for process measurement and control products!

Photo by Craig Terry, courtesy of Chemical Engineering Program at Rowan University

In-Line Ultrasonic Flowmeter

Digital Paddlewheel Meters

For Sales and Service, Call TOLL FREE

Cover Art: Based on an Original Norman Rockwell illustration

Hot Water Meters for

Circle 2 or Request Info Instantly at www.FlowControlNetwork.com

COPYRIGHT 2011 OMEGA ENGINEERING, INC. ALL RIGHTS RESERVED

Vol. XVII, No. 6

analog-to-digital valve upgrades

20 2011 Flow Control Innovation Awards

34 Ge F. Fischer Tells It His Way

reflections from a pioneer of flow measurement

37 Flow Problems Solved

forum selections from pipeflowcalculations.com

4 VIEWPOINT keeping it simple

part IV: vortex flowmeter postmortem

40 THE PUMP GUY

pump problem solved through observation & deduction

The 2011 Flow

47 THINK TANK pressure regulators

I NEED SOLUTIONS, NOT EXCUSES.

Your products must perform perfectly, right

Fluid control solutions. Right. Now.

1-800-972-ASCO (2726) | www.asconumatics.com/RightNow | e-mail: info-valve@asco.com

s i sit here on the morning of the u.s. Memorial

on the lenders side, were

EdItoRIAL AdVISoRy BoARd

If youve paid for automatic control valves,

Circle 4 or Request Info Instantly at www.FlowControlNetwork.com

news & notes

The Secret Behind NISTs New Gas Detector

race gas detection, the ability to

gas can indicate a problem exists

Avg. Annual Air Filtration Equip. Expenditures in

Circle 5 or Request Info Instantly at www.FlowControlNetwork.com

news & notes

Process Automation Market to Continue Recovery Through 2011

Automation Expenditures for

EUROPE, M. EAST, AFRICA

Source: ARC Advisory Group

at 12.3 percent, China at 7.4 percent,

best practices & standards

Fieldbus Foundation Releases Flow Transducer Block Specification

the local input/output blocks required to

critical procedure of totaling different

Innovative Flow and Pressure Solutions

7641 N. Business Park Drive

Alicat Scientific, Inc. is a Halma Company Alicat Scientific, Inc. 2011

Part IV: Vortex Flowmeter Postmortem

or the past few months, I described problems with a new

Situations where more than one problem

technician visit the plant to obtain information that was relayed

Transmitter & indicator

David W. Spitzer is a regular contributor