Flow Control: Technology information & new products for fluid handling engineers

Definer 1020 Primary Gas Flow Piston Prover
By Bios International
www.biosint.com

Bios International’s Definer 1020 is a primary gas flow piston prover for gas flows from five to 500 standard liters per minute. Previously large bell provers were required at flow ranges of 500 SLM. Now with the Definer 1020, users can employ a primary flow standard that can sit on a laboratory bench. The Definer 1020 is a fully automated instrument that provides fast, accurate flow measurements in a benchtop instrument.

Bell provers are typically large, permanently mounted instruments that require oil to function. The Definer 1020, on the other hand, is a portable benchtop instrument that requires no fluids to operate; and it can take measurements with the push of a button.

The Definer 1020, which offers accuracy of 0.25 percent, is significantly smaller, faster, and easier to operate than previous iterations of bell prover technology.

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A2B Wireless Communication System
By BS&B Wireless LLC
www.bsbsystems.com

BS&B Wireless LLC’s Wire A2B Simple Industrial Wireless Communications System is designed for situations requiring only a single device to be monitored. The basic functionality of the A2B modules is to sense analog and/or digital signals on one module and reproduce the signals on the other module using wireless communications. The analog inputs and analog outputs may vary within 4-20mA current or zero to five VDC. The modules operate on external power or battery backup power.

The A2B module system is bi-directional and eliminates the need for wiring that would otherwise be necessary between module locations. Each module is capable of sensing three analog and three digital inputs and re-generates three analog and three digital outputs. Module A and Module B can either function as a Local or Remote module.

Each module consumes 1.8 Watts (max), when operated with external power source with its full capacity of all output channels loaded and its radio in active condition. During battery mode, only one analog channel and all digital channels are active.

Application Note: An existing plant uses a pressure-relief valve to record and report electronically as part of emissions standards compliance. Although the sensor itself is a simple pressure switch, the installation presents special challenges. For instance, wiring installation requires cutting through building insulation. Concerns of asbestos-based materials existing in the walls are also an issue. The cost of installation is many times higher than the cost of the simple hardware. Applying the pressure switch using wireless communication technology removed the uncertainties of such upgrades in this plant environment.

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Burkert Type 8620 Multifunction Controller
By Burkert Fluid Control Systems
www.burkert.com

Burkert Fluid Control’s 8620 Multi-function Controller is a microprocessor control system designed to automate the control of process variables within a water treatment system (e.g., boiler or cooling system). Sophisticated electronics and state-of-the-art control algorithms ensure optimum process control is maintained at all times, with the minimum of operator intervention.

The controller is capable of processing up to four analog inputs, four digital inputs, five relay outputs, four transistor outputs, and optional four analog outputs (4-20 mA) simultaneously, thus offering almost unlimited possibilities in process automation systems, such as cooling towers and RO systems.

This multifunction controller has allowed users to save money on multiple controllers and additional software because the 8620 can process multiple inputs, outputs, and algorithms without the necessity for high-cost PLCs.

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98 Series Pressure Management Control Valve
By Cla-Val
www.cla-val.com

Cla-Val’s all-hydraulic 98 Series Pressure Management Valve controls water distribution system pressure based on actual demand rather than on anticipated peak demand levels. This is desirable because during off-peak hours (such as at night) when demand falls, pipelines are over-pressurized, leaving them vulnerable to breaks and an increase in background leakage. In the event of sudden, higher demand, such as fire flow, the 98 Series valve automatically increases system pressure to meet requirements. When demand again decreases, the valve automatically lowers pressure accordingly.

The self-contained 98 Series Pressure Management Valve utilizes a cutting-edge pilot system comprised of the CRD2S pilot control and X78 adjustable stem valve that senses actual system demand and responds by automatically lowering or raising pressure to meet current requirements. It provides this pressure control completely independent of external devices, such as orifice plates, meters, or SCADA communication, making it a good fit for remote locations that do not have electrical power or are difficult to access for manual setpoint adjustments.

Application Note: At several water utility system field test locations in the United States, Canada, and other international sites, the 98 Series Pressure Management Valves have enabled operations personnel to automatically vary system pressures to meet actual demand without having to make manual adjustments as demand increases and decreases and without employing external devices, such as orifice-plate meters or SCADA communication. This is desirable because many of the test site locations are remote or not easily accessible.

The water utility companies that have participated in field-testing have experienced immediate benefits, including less water lost through background leaks and pipe breaks, fewer service interruptions, and reduced pumping costs. Because the valves provide all of these benefits hydraulically, the water companies are also able to protect their systems against the damages that result from over-pressurization, even in the event of loss of electrical or battery power.

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Oxygen Series Electronic Valves
By Clippard Instrument Laboratory Inc
www.clippard.com

Clippard Instrument Laboratory’s O Series electronic valves are two- and three-way solenoid valves, which have been cleaned, inspected, assembled, and tested for use in oxygen-enriched environments.

Many existing solenoid valves contain organic and inorganic contaminants, which can be a safety hazard when used with elevated concentrations of oxygen. The O Series valves are assembled in a clean environment — an isolated room, maintained at a positive pressure with HEPA-filtered air. All wetted parts are ultrasonically cleaned, dried, and inspected prior to assembly. Valves are assembled without organic sealants, adhesives, or lubricants. They are tested using high-purity nitrogen and are double bagged to maintain cleanliness until use.

O Series valves are ideal for systems using oxygen or oxygen-enriched air, and for those that are sensitive to contamination. The valves are also a good fit for analytical instrumentation where organic sealants, lubricants, or inorganic particles have previously caused problems.

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DH3 Digihelic Differential-Pressure Controller
By Dwyer Instruments
www.dwyer-inst.com

Dwyer Instruments’ DH3 Digihelic Differential-Pressure Controller is a three-in-one instrument, possessing a digital display gauge, control relay switches, and a transmitter with current output all packed in the popular Photohelic gauge-style housing. Combining these three features enables several instruments to be replaced with one product, saving the end-user inventory, installation, time, and money.

The Series DH3 Digihelic Controller allows the selection of pressure, velocity, or volumetric flow operation in several commonly used engineering units. Two SPDT control relays with adjustable deadbands are provided along with a scalable 4-20 mA process output.

Application Note: The DH3 has shown promise in fan air-handling applications. In the past, users in this area had to custom order every gauge to match their particular fan’s curve. This method would incur added costs and additional lead times. With the DH3, users can program any Digihelic controller in their facility.

Likewise, pharmaceutical and semiconductor companies are using the DH3 controller to their advantage, employing the controllers features for locking out users so they can view but not alter parameters. In the past, this would have required a mechanical lockout installation.

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DiamondFaces Mechanical Seal Coating
By EagleBurgmann
www.eagleburgmann.us

EagleBurgmann’s DiamondFaces® mechanical seal coatings are synthetically manufactured, ultra-pure crystalline diamonds with the same outstanding properties as the natural stone — the hardest material known to man. A CVD (Chemical Vapor Deposition) coating process is used at very high temperatures to deposit a high coating thickness of 8µm on silicon carbide faces, while keeping the seal faces flat to within 0.6 microns or 0.0000232 inches. This diamond coating is applied to both the rotating and stationary faces of a seal face pair.

This process and resulting product are quite revolutionary in many ways. Seal faces must be flat to function as a mechanical seal or leakage will occur. Therefore, the deposition method is critical to the application of the diamond to the face. EagleBurgmann’s CVD process excels at maintaining flatness and building a suitable deposition layer. DiamondFaces improves existing sealing technology by decreasing mechanical seal sensitivity while increasing reliability.

The heart of any mechanical seal is the faces. Previous innovations in this area included the introduction of silicon carbide to seal faces. DiamondFaces improves the silicon carbide material by making the working part of the faces harder and creating less friction between the faces. With current uncoated silicon carbide faces, dry running will damage the faces beyond repair within 30 seconds. With DiamondFaces, a seal will achieve approx. 10 hours of dry-running capability with complete recovery of sealing function after upset.

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FLOMIC FL 50X4 Ultrasonic Flowmeter
By Elis Plzen a.s.
www.elis.cz

Elis Plzen’s FLOMIC FL50X4 ultrasonic flowmeter is a no-moving-parts, battery-powered device that operates without any external power source — driven solely by a 3.6 volt Li battery with a lifetime of eight years when providing sample flow measurement once per second.

The FLOMIC flowmeter enables the network operator to select data storage options, including instantaneous flowrate, total volume passed through the meter sensor, fluid pressure, minimum and maximum flowrate over time, as well as archiving of measured data within the meter’s memory unit in specified intervals.

The FLOMIC flowmeter offers single- or dual-beam capability in a compact, Class IP68 housing (sensor and unit). Supports operation temperature up to 50 C, extremely low hydraulic losses, minimum maintenance requirements, independent power supply, higher long-term stability of measurement precision, auto-diagnostic features, electric output signal (pulse and current 4-20 mA), RS232 communication interface, USB, and a data-transfer system using GSM technology.

The FLOMIC FL 50X4 flowmeter is a particularly good fit for remote applications where power supplies are difficult to reach.

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The Family of In-Line Chlorine & Chlorine Dioxide Sensors
By EMEC Americas
www.emecpumps.com

EMEC Americas’ two new amperometric sensors are designed for monitoring free chlorine and chlorine dioxide in water treatment flow streams. These new sensors mount directly into the treatment flow stream, which eliminates the drain bypass that other chlorine flow sensors typically require. This results in savings of up to 135,000 gallons of water per sensor, per year, which could equal a savings of $250,000 per year in some markets.

The key feature of these two new sensors is that they mount directly in the flow stream at operating pressures up to 115 PSI and temperatures up to 122 F. This saves money for the water utility by eliminating the discharge to drain of large amounts of water. Designed to work with EMEC’s new LD Controller Series, these probes can detect the free chlorine and chlorine dioxide levels of zero to 10 parts per million (PPM).

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Rosemount 8714i Magnetic Flowmeter Meter Verification
By Emerson Process Mgmt, Rosemount Flow Division
www.rosemount.com

Emerson Process Mgmt, Rosemount Flow Division’s patent-pending Rosemount 8714i Meter Verification technology is the first in the world to provide integrated In-Situ verification for magnetic flowmeters. This technology verifies the transmitter and sensor health, as well as calibration, without the need for process shutdown, sensor removal, or specialized external equipment. This innovation enables users to take a significant step forward in how they maintain and verify their magnetic flowmeters, while allowing them to keep their process available and minimize their maintenance costs. With Rosemount E-Series Universal transmitter capabilities, 8714i Meter Verification is available to any user of magnetic flowmeter technology via a user-friendly interface that provides clear pass/fail results.

Prior to this innovation, users were required to either shut down the process and send the meter to a certified calibration facility for validation or purchase costly external equipment. Often the external equipment also required specially trained service personnel to connect the equipment, perform the tests, and analyze the data to ultimately make the decision if the flowmeter was still healthy.

8714i Meter Verification makes magnetic flowmeter verification simple and easy, with access to this technology available through the local operator interface, field communicators, or asset management software. By testing the entire transmitter architecture, sensor coil and electrode circuitry, interconnecting cabling, and the magnetic field, this technology confirms that everything is performing correctly and is within user specified test limits.

Application Note: To comply with the EPA’s annual effluent flow certification requirements, one user was pulling a magnetic flowmeter from the line and sending it back to a certified calibration facility to have an annual calibration and verification performed on the meter. This was costing the user $4,000 per point for the calibration, in addition to the process downtime to remove the sensor and install a replacement. With 8714i Meter Verification, this user no longer needs to spend the time and money shutting down the process and pulling the meter from the line. They simply run the verification diagnostic through the control system and get the certification needed to satisfy the EPA’s requirements.

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Rosemount 3051S Wireless Flowmeters
By Emerson Process Mgmt, Rosemount Measurement Division
www.rosemount.com

Emerson Process Mgmt, Rosemount Measurement Division’s Rosemount 3051S Wireless Flowmeters are part of Emerson’s Smart Wireless solution set, which aims to provide a cost-effective and easy means to add new flow measurements in the plant. These new solutions leverage the industry standard HART protocol and Smart Wireless self-organizing wireless networks to allow seamless and secure integration of the flow data into existing information systems. The flow data can be gathered via standard Web interface or integrated directly into existing host systems.

The technology behind the 3051S Wireless Flowmeters is robust, delivering greater than 99 percent data reliability. The wireless communication is automatically set up by the network manager residing in the Smart Wireless Gateway and requires no additional user intervention or special tools. The 3051S Wireless Flowmeter solutions include compact and integral orifice flowmeters, conditioning orifice flowmeters, and Annubar flowmeters.

Rosemount 3051S Wireless Flowmeters arrive factory-configured, leak-checked, and ready for installation. Wireless technology married with industry-leading primary elements allows users to make measurements where they have not been able to before, either because of physical or economical constraints. This additional insight enables increased efficiency, reduced maintenance, extended asset life, and helps users meet challenging environmental and safety goals.

Testimonial: Wheeling Pittsburgh Steel, a manufacturer and fabricator of selected metal products, recently expanded its product offering, which required more run-out table cooling water to maintain quality grain structure. Unfortunately, as the new product was being rolled, the target coiling temperature could not be achieved because incorrect amounts of cooling water were being applied. The customer installed Rosemount Wireless Flowmeters to measure water flow for four of the sixteen curtains on the run-out table in the finishing mill. Since the addition of the flowmeters, coiling temperature rejects have been almost entirely eliminated and productivity has improved. The customer plans to install Rosemount Wireless Flowmeters on its remaining 12 curtains. The Rosemount 3051S allowed Wheeling Pittsburgh Steel to gain process insight in areas where wiring devices had been too costly.

“We are building an infrastructure that opens up opportunities for more applications. The result is better information from difficult-to-reach areas of the mill, and this is helping our personnel prevent unscheduled downtime, meet customers’ quality requirements, and optimize productivity.” — Gary Borham, Mill Operations Manager, Wheeling Pittsburgh Steel

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Proline Promass P Hygenic Coriolis Flowmeter
By Endress+Hauser
www.endress.com

Endress+Hauser’s Proline Promass P Coriolis flowmeter is designed for users in the life sciences industry that require a fully drainable, hygienic flow measurement system. The Promass P offers 0.1 percent traceable calibration uncertainty, 0.0005 g/cc density measurement, and exceptional accuracy during cleaning or periods of entrained gas. The meter guarantees compliance with new ASME-BPE 2007 standards, which mandate changes regarding customer documentation, designs for sterility and cleanability, welding and evaluation techniques, and contact surface finishes. Full documentation packages ensure GMP conformance.

Specifically, the Promass P offers certification and inspection certificates for ASME BPE CoC to relevant scope: EN 10204 3.1 for materials, surface finish, and delta ferrite. All process-wetted materials are 316L/1.4435. In fact, this flowmeter is designed to comply with ASME BPE, ISPE, FDA, EHEDG, and 3-A. The sensor design is fully welded and hygienic. It’s fully drainable in horizontal-mount positions, ensuring no holdup volume. The meter supports mass flow measurement up to 2,570 lb/min, temperatures to 392 F, and pressures to 914 PSI.

Promass P is suitable for use in PAT applications for the continuous monitoring of critical quality process variables, such as mass flow, volume flow, density, and temperature.

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PlantTriage Performance Supervision Software
By ExperTune Inc
www.expertune.com

ExperTune’s PlantTriage Version 7.0 software finds flow control problems and simplifies maintenance planning. The software connects to the plant control system, using industry-standard OPC communications. By extracting real-time data, the PlantTriage software detects and prioritizes specific flow control problems. For example, the software can find failing flowmeters, sticking control valves, and poorly tuned flow control loops. Diagnostics are reported to the user via a Web browser interface. Suggested corrective actions are also included in the software reports.

PlantTriage operates with just about every control system on the market. The software also scores diagnostic results based on economic importance. The standard reports that come with PlantTriage support both preventive and predictive maintenance strategies. Users can also deliver reports to their e-mail inbox on a scheduled basis.

Application Note: At a plastics plant in New York, one engineer has been dubbed “The Valve Whisperer” for her uncanny ability to identify failing control valves. She uses PlantTriage to pinpoint failing valves and schedule them for maintenance. The improved process stability realized as a result of PlantTriage has saved over $240,000 per year.

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Flowserve Valtek Stealth Valve Trim
By Flowserve
www.flowserve.com

Flowserve’s Stealth Valve Trim offers noise reductions of up to 35 dBA. Noise is a very serious issue for maintenance personnel, as severe harmonics can damage hearing very quickly and the frequency vibrations can damage or, in the most extreme cases, even destroy equipment. Noise cannot exceed 90 db for human hearing; yet, without noise reduction, plants often easily surpass this limit.

The Stealth Valve retainer is produced from a series of three unique discs that are laser cut from sheet metal. These three discs are stacked together in a repetitive sequence to form the flow passages of the valve retainer. The geometry of these discs is highly engineered to achieve maximum noise attenuation and desired flow. The discs are vacuum brazed to each other.

The Stealth trim’s ability to gradually reduce pressure without generating high velocities is important for the reduction of noise in the process line. In addition to gradually reducing the pressure, Stealth takes advantage of frequency shifting by providing small outlet holes, which raise frequency and lower noise.

The exit passages are also angled to direct the flow to the valve exit. This feature increases the flow capacity of the valve and lowers the noise by reducing exit turbulence. Another important feature for noise control is the patented WaveCracker technology WO 2006/093956. WaveCracker provides extra noise attenuation without increasing the number of pressure-reducing stages. This is achieved by offsetting the laser cut discs slightly, changing the flow path geometry and creating an extra dimension to each flow passage. Testing has proven this feature alone can reduce the measured noise up to 10 dBA in some cases.

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Type 530 AquaTap Recirculating Laboratory Faucet
By GF Piping Systems
www.gfpiping.com

GF Piping Systems’ Type 530 AquaTap Recirculating Laboratory Faucet provides clean water at the point of use for optimum water quality. It features a patented flow-through head design that eliminates deadlegs and optimizes flow characteristics, offering unprecedented recirculating capacity at a minimal pressure drop to the main water line.

To facilitate complete installation versatility, a variety of components are available, including undersink shutoff valves, tubing, tubing interconnects, and compression adapters. The faucet can be deck or wall-mounted, and the IFD (Inline Flow Diverter) can be ordered with up to three port configurations, allowing connection of up to three faucets off the same IFD. Initial capping of unused ports allows for future system expansion.

The faucet incorporates a patent-pending innovation in the form of GF Piping Systems’ Inline Flow Diverter (IFD) technology. Featuring maximum recirculating faucet flow with minimal pressure drop across the main UPW loop, the IFD is specifically designed to maximize the performance and ease the installation of the Aqua Tap faucet into new or existing systems.

Testimonial: A major semiconductor testing laboratory was experiencing poor water quality and high bacteria counts from its DI water faucets. Existing faucets were replaced with the AquaTap system, and the bacteria counts fell to an almost nonexistent level. In follow-up, the company said, “We no longer need to leave the faucets running to reduce bacteria, and as a result are saving significant amount of wasted DI water.”

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Grundfos MAGNA Variable-Speed Circulator Pump
By Grundfos Pumps
www.grundfospumps.com

Grundfos Pumps’ MAGNA Variable-Speed Circulator Pump is an innovative variable-speed, wet-rotor circulator with permanent
magnet motor technology. It is capable of saving up to 80 percent in energy costs over older, lower-efficiency circulators.

Featuring an integrated variable-speed drive with patented, intelligent AUTOADAPT function, the pump regularly adjusts the proportional pressure and sets a more efficient performance curve whenever possible. Permanent-magnet motor technology is very efficient and allows for extremely precise speed control.

The MAGNA pump holds an “A” rating (the highest) with Europe’s energy labeling system. The pump’s Smart AUTOADAPT function means no manual setting adjustments are needed in about 80 percent of applications.

Flexible flange connections and short flange-to-flange length make for easy replacements without piping modifications. Wet-rotor technology means the pump is cooled and lubricated by the water it pumps. There’s no fan noise. Permanent-magnet technology means the pump has a brushless motor, which also contributes to its quiet operation and long lifecycle.

Application Note: The MAGNA pump has been installed in a custom motorcycle company’s new world headquarters in Newburgh, NY. A radiant heating system warms portions of the facility. The largest of three key hydronic zones at the facility is a snowmelt system, which heats the parking garage outdoor ramp to provide a safe, ice-free path for moving custom bikes in and out of the shop.

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GT1000 PDP Valve
By GT Flow Control
www.gtflowcontrol.com

GT Flow Control’s GT1000 PDP (Parallel Disc Pressed) Valve is a solid metal-to-metal, zero-leak device with no synthetic or flexible material in the flow area of the valve. This design was achieved by pressing the disc linearly into the seat of the valve, creating an even load on the entire circumference of the seat for a 100 percent bidirectional bubble-tight seal, using a very low operating torque. This new technology allows the valve to compete with larger, heavier, and more expensive globe, gate, and ball valves, not only in performance characteristics but also in cost of installation and maintenance.

The GT 1000 PDP comes in flange, lug, wafer, and butt-weld designs. It can be manufactured out of most popular materials and it can have PTFE coatings. ANSI 150, 300, and 600 valves are available with operating temperatures from -40 F to 1,400 F.

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Insta-Valve Plus
By Hydra-Stop, A Division of ADS LLC
www.hydra-stop.com

Hydra-Stop’s patented Insta-Valve Plus design makes installation simple — just install the fitting, make the tap, then install the valve. Insta-Valve Plus becomes part of the permanent assets of the pipeline owner and will continue to be used in the future by its operators to gain control, with valve isolation, of the utility system in the event of contamination, emergency repair, or even planned maintenance. Once installed, Insta-Valve Plus operates with a standard valve key.

Key features of Insta-Valve Plus include easy installation; a bullet stopper head for resilient seat wedge line stopping; under-pressure installation up to 150 PSI in four-inch to 16-inch water mains; a newly added centering plate; and a compression-molded hyperbolic parabola seating surface for optimized sealing.

Testimonial: The town of Bernillo, NM was in need of isolation valves. HDR Engineering chose Insta-Valve Plus as the solution.

Gabriel Alvarado with HDR Engineering said, “The town needed a way to isolate the system, but had no isolation valves. Insta-Valve Plus valves were installed in strategic locations to enable future isolation without shutting down large portions of the system. Adding conventional valves was not an option because the town would have to be shutdown. Since the installation of the 13 Insta-Valve Plus valves, Bernillo has indeed been able to isolate sections of the system as needed without shutting down.”

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PIM Series Pump Diagnostic Pressure Sensor
By ifm efector inc
www.ifmefector.com

ifm efector’s PIM Series pump diagnostic pressure sensor detects potential pump damage caused by cavitation, trapped air or gas, blockages, and deposits. The PIM sensor performs two functions in one compact housing — the sensor continuously monitors the system pressure of a pump and, at the same time, provides independent diagnosis of the pump’s condition. The pressure sensor is designed and approved for sanitary applications.

Operating as a pressure sensor, the PIM Series sensor provides numeric indication of the operating system pressure. The sensor’s output can be configured as a switching output with hysteresis or window function, or as a scaleable analog output.

Performing as a pump diagnostic sensor, the sensor detects potential pump damage caused by cavitation, trapped air or gas, blockages, and deposits.

Pumps are used for conveying media in many applications in the process industry. Often these pumps are operated without being monitored, so possible damage to the pump is detected very late, if not too late. The PIM pressure sensor provides condition-based monitoring of a pump that leads to longer maintenance intervals. Thus, the uptime of the plant is increased and damage is avoided.

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IFC 100 Signal Converter
By KROHNE Inc
www.krohne.com

KROHNE’s IFC 100 Signal Converter is a unique solution that works with the complete range of KROHNE’s OPTIFLUX series of electromagnetic flowmeters. The IFC 100 offers diagnostic capabilities not found in other converters in its price range, including diagnostics of instrument, installation, and application. For example, the IFC 100 is able to measure electrode resistance for the indication of gas bubbles or solid particles and electrode noise for chemical resistance. Coil resistance is monitored to assess magnetic field quality and flowmeter temperature.

Application Note: In a drinking water plant in the Czech Republic, the IFC 100 was applied to a flow measurement application for whitewash at ambient temperature and pressures to 400kPag/60PSIG on a 1.5-inch line with the meter connected by hosepipe four feet from a positive-displacement pump.

Flow measuring range was zero to 10m3/h or zero to 45 USGPM. This application has always been a challenge, as the whitewash forms a layer on the inside wall of the piping, and the meter, causing up to a 35 percent constriction on flowrates after a month in service, which typically causes meters to fail due to a loss in discernible flow signal.

Despite the difficult conditions of this application, the IFC100 was able to reliably measure flow for a full three months with no failures. As such, the user has decided to adopt this product while also extending its maintenance program to clear the lines every second month, instead of on a monthly cycle, thereby greatly impacting the company’s bottom line.

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LM2D Two-Dimensional Laser Scanner
By K-Tek Corp
www.ktekcorp.com

K-Tek’s LM2D Laser Scanner is a noncontact level measurement device that eliminates the need for calibration and routine maintenance. The LM2D uses two different noncontact technologies — laser for surface profiling and Doppler radar for noncontact speed measurement of material flowing on a conveyor belt.

The LM2D consistently matches the performance of the existing conventional technology, with accuracy of 0.5 percent to 3.5 percent (typically 1.5 percent).
The LM2D incorporates a noncontact belt speed sensor that uses Doppler radar to measure conveyor speed. The scanner head scans the profile of the flowing material on the belt. An on-board microprocessor uses the information from the scanning head to calculate volume and mass throughput in real time. An integral laser pointer is provided to aid in alignment. Installation is quick, requiring only a few minutes, as compared to belt scale systems, which can take many hours or days to install.

Application Note: A large fertilizer producer in Russia had a problem with its inventory measurement system, which was based on conventional belt scales. The existing belt scales required regular maintenance and produced inaccurate final product inventory.

The LM2D was installed on the final product conveyer line. After the first few hours of operation, the LM2D belt conveyer scanner showed volumetric and weight measurement accuracy of better than 0.5 percent. Due to its noncontact nature, the LM2D proved to be easy and quick to install, with no maintenance and no requirement for routine calibration.

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Kurz 6500 Gold Series Switch
By Kurz Instruments Inc
www.kurzinstruments.com

Kurz Instruments’ Olympic Gold Series 6500 Flow, Level, Interface, and Temperature Switch features simple, intuitive electronics that enable pushbutton configuration in the field, without tools, meters, or process flow modulation. The user-friendly interface allows operators to make all on-site configuration changes within minutes. The units contain no jumpers or dip-switches. Configuration can be easily accomplished with the display panel or via Modbus.
With a smart switching power supply (12/24 VDC and 115/230 VAC), six built-in timers, and a variety of mounting options/styles/sizes; the Gold Series eases the installation process.

Testimonial: “As a developer of several economical and environmentally acceptable power generation facilities, ranging in size from 1MW to 49MW, Alliance Power has had a lot of experience with flow switches over the past several years. Because of that experience, Kurz asked us to evaluate its new flow switch line.

“What we found was that Kurz had transformed ancient technology used in everyday applications by making it better, faster, and user-friendly. Their flow switch was not like most others on the market, which were based on 40-year-old technology, with a need to adjust potentiometers, jumpers, or other settings just to get [them] working. Kurz was introducing a truly microprocessor-based ‘click and get to work’ flow, level, and interface product, which is as dependable and reliable as I know Kurz products to be. With a simple interface and a standard three-year warranty, I’ll never want any other flow, level or interface product again.” — Jim Michael, President, Alliance Power

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L.J. Star Pharmaceutical Bubble Trap

By L.J. Star Inc
www.ljstar.com

L.J. Star’s Pharmaceutical Bubble Trap is designed to remove unwanted gas/air bubbles from process fluids. Available in standard four-inch to 10-inch sizes and custom designs.

L.J. Star’s Pharmaceutical Bubble Trap is the first device designed to be crevice-free and self-draining, eliminating bacteria traps that could contaminate pharmaceutical product and cost thousands of dollars.

Washdown is simple and efficient. The Bubble Trap interior surfaces are angles or arcs so all liquid will drain into the outlet. The exterior is also self-draining to accommodate washdown cleaning. Other designs may trap tiny amounts of liquid that could potentially harbor bacteria. In addition, disassembly and reassembly are quick and easily accomplished. The L.J. Star Bubble Trap is also ASME BPE 2007 compliant, with full traceability on all wetted components.

Application of Note: A skid manufacturer that serves major pharmaceutical companies recently asked L.J. Star to improve upon the designs of the bubble traps currently available, so it could have a solution that met all of the key requirements of pharmaceutical applications. As the development team progressed in creating a bubble trap that was both effective and hygienic, L.J. Star consulted three clients who helped to fine-tune the design. Beta testing started in mid 2007, and L.J. Star’s Bubble Trap has been proven in service in multiple installations since then.

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FlowCERT/DUET Ultrasonic Flowmeter
By Pulsar Inc
www.pulsar-us.com

Pulsar’s FlowCERT electronics with the twin-transducer DUET (Double Ultrasonic Echo Transducer) is an accurate and repeatable open-channel ultrasonic flowmeter, featuring +/- 0.5mm accuracy. The meter is designed for measuring flow in flumes and weirs with a temperature-independent, reliable measurement and high-capacity logging facilities.

The FlowCERT with DUET offers a new approach that provides accuracy previously unachievable in an ultrasonic system. DUET compensates automatically for significant changes in air density and hence sonic velocity caused by solar radiation.

Conventional temperature compensation systems become inaccurate when installed in exposed locations. These systems are generally slow to react to changing conditions due to thermal lag and do not respond accurately to air density in conditions of bright sunlight.

DUET offers a unique solution to this problem (patent pending). Both transducers fire together, and by continuously monitoring the phase difference of the echoes as they are picked up by the lower transducer, and because the distance between the transducer faces is known and constant, the speed of sound is continuously updated.

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Flowell Liquid Flowmeter
By SA Fluigent
www.fluigent.com

SA Fluigent’s Flowell Liquid Flowmeter is designed for extremely sensitive and fast measurements of ultra-low liquid mass flows. This particularly small and light device operates with high pressure resistant total media isolation and hardly any
dead volume.

The Flowell is an accessory of Fluigent’s MFCS, which enables users to measure flowrates with a very high precision. The unique performance of this device is based on the CMOSens sensor technology, which combines a high precision sensor element with the amplification and A/D converter circuit and digital signal processing on one single CMOS chip. This results in high resolution, fast response time, and large dynamic range at lowest power consumption. Excellent chemical resistance and biocompatibility is also a key feature of this product, as the medium only contacts the internal fused silica capillary, PEEK screw fittings, and Polypropylene.

This multi-sensor device is designed specifically for microfluidic systems. Typical applications of the Flowell Liquid Flowmeter include precise liquid flow measurement and metering for liquid chromatography, lab-on-a-chip systems, drug delivery, life sciences, and quality testing.

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Sage Prime Thermal Mass Flowmeter
By Sage Metering Inc
www.sagemetering.com

Sage Metering’s Sage Prime is an industrial thermal mass flowmeter for gas mass flow, featuring an organic LED (OLED) with high resolution, low power dissipation, and unusual clarity. Formatted with both graphical and numeric indication of flowrate, the easy-to-read display also reports totalized flow and temperature, as well as the raw calibration milliwatts (mw) for ongoing diagnostics. Sage Prime is designed for ease of installation, with a new dual-compartment windowed explosion-proof enclosure. The rear compartment is completely independent from the electronics side and provides a custom-designed, pedestal-type set of terminals, providing ease-of-access even for large gage wires (up to 14 gage). The terminals are well marked, and output 4-20 mA of flowrate, 24 VDC pulses of totalized flow, and Modbus-compliant RS485 RTU communications. The meter is powered from either 24 VDC or 115/230 VAC operation, or optionally 12 VDC (for solar energy applications). Power dissipation is under 2.5 watts.

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Innova-Sonic In-LineUltrasonic Flowmeter Model 206
By Sierra Instruments Inc
www.sierrainstruments.com

Sierra Instruments’ Innova-Sonic In-Line Model 206 Ultrasonic Flowmeter is a digital correlation transit-time device designed to give the end-user high performance at an affordable price. The Innova-Sonic features advanced PicoFly measurement technology, representing an order-of-magnitude improvement in transit-time measurement technology, allowing far superior response to changes in flow (with much greater resolution) and outstanding low-flow detection.

Innova-Sonic In-Line features patented ultra-precise PicoFly measurement technology. An industry first, this advanced technology allows the ultrasonic transit time to be measured in picoseconds 10-12 (one trillionth of a second) for superior resolution and extreme low-flow detection compared to typical nanoseconds 10-9 (one billionth of a second) processing.

In addition, Innova-Sonic In-Line is designed primarily as an alternative for magnetic flowmeter applications, with several clear advantages. The 0.5 percent of reading accuracy is as good as a typical magnetic flowmeter, but the ability to measure down to zero flow and measure virtually any clean liquid regardless of conductivity sets Innova-Sonic In-Line apart.

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AutoJet Model 1550 Modular Spray System
By Spraying Systems Co
www.spray.com

Spraying Systems’ AutoJet Model 1550 Modular Spray System includes everything needed to precisely control the operation of up to eight automatic spray nozzles in a compact, portable package weighing less than 50 pounds.

Standard features include an air-operated, double-diaphragm pump, NEMA 4 or NEMA 4X control panel, air and liquid pressure regulators, and control valves for liquid recirculation. All wetted surfaces are stainless steel, Kynar, Delrin, or PTFE.

The AutoJet Model 1550 Modular Spray System is self-contained and can be set up in a matter of minutes to optimize the performance of automatic spray nozzles. On-board spray control technology allows users to set the following spray parameters:
• Delay time – time between when a sensor detects an object to the time the system sprays the object.
• Spray time – duration of spray.
• Repeat time – time between sprays.
• Duty cycle – percent of time the spray is “on” when using PWM flow control.

Application Note: A user applying egg wash on tortillas had planned to create a spray control system using a PLC, which would have required significant programming for efficient operation. The AutoJet Model 1550 Modular Spray System with on-board spray control capabilities provided accurate timing control right out of the box. The self-contained system, with an air-operated double-diaphragm pump, was able to efficiently move the egg wash from the source to the spray nozzles and was quickly integrated into the customer’s production line. In addition, the advanced Pulse Width Modulated (PWM) flow control significantly reduced overspray.

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MBI Advanced Ceramic Bearing Design
By SPX Flow Technology
www.spxpe.com

SPX Flow Technology’s patented, dry-running, all-ceramic bearing is designed specifically for the company’s line of bottom- and top-entry mixers.

The ceramic bearings are operated without any lubrication or particulate generation. Particulate contamination or lubricant contamination cannot be tolerated in pharmaceutical or biotech applications. Long life and cleanability are assured.

Traditional bearings require some form of lubrication. The MBI bearing design is a prime component in the development of a new line of process mixing equipment that eliminates the need for mechanical seals.

Traditional steel-on-steel bearings generate particulate that can clog filters or ruin a product. Ceramic bearings contain no metallic components. Races and rolling elements are high grade, USP Class VI ceramics.

The all-ceramic bearing is a good fit for pharmaceutical, biotechnology, and food and beverage applications.

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TopGear MAG Magnetically Driven Internal Gear Pump
By SPX Process Equipment, Johnson Pump Brand
www.johnson-pump.com

SPX Process Equipment, Johnson Pump’s TopGear MAG is a magnetically driven internal gear pump that offers a sealless, leak-proof operation for low and high viscous liquids. The pump is specifically developed for hazardous or toxic liquids or liquids that are difficult to seal off.

Total containment of the liquid inside the pump is achieved using a hermetically sealed can, which effectively isolates the liquid from the surrounding environment. This eliminates the need for shaft seals and the associated wear and leakage that would normally occur.

TopGear MAG is equipped with a unique new development — an integrated cooling pump that provides a forced recirculation of the pumped liquid through the bearings and magnet coupling. Another important feature of the pump is the large gap between the inner magnets to minimize internal friction losses. This design ensures a correct cooling of the bearings and magnets independent of operation pressure and liquid viscosity.

Simple inspection and maintenance is enabled by an easily disassembled back and front pullout design. The pump is available in cast iron and stainless steel and is equipped with silicone carbide bearings and can be made of chemically resistant Hastelloy C4. TopGear MAG pumps provide a maximum capacity of 80 m3/h, a maximum differential pressure of 16 bar, and can operate on liquids with a maximum temperature of 260 C.

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HFM-I-400 Series Mass Flowmeters
By Teledyne Hastings Instruments
www.teledyne.com

Teledyne Hastings Instruments’ HFM-I-400 Series is a new family of mass flow instruments, which is specifically designed to meet the needs of the industrial gas flow market. The HFM-I-401 measures gas flow from zero to 10 SLM up to zero to 350 SLM; the HFM-I-405 measures gas flow from zero to 100 SLM up to zero to 2,500 SLM.

The “I” family features an IP-65 enclosure (Class 1, Div. 2 hazardous location approval pending), which allows the use of the instrument in a wide variety of environments. All models have been certified to the appropriate CE standards. In addition, each flowmeter can be powered by either +24 or +/- 15 VDC power supply. Each model provides, simultaneously, both analog and digital output. One of the innovative digital output options is Ethernet. The electrical connection can be made either via a terminal strip located inside the enclosure or through an IP-65 compatible electrical connector, which can be quickly connected. The electronics module can be mounted either locally on the flow sensor, or remotely (up to 10 m) using a shielded interface cable.

Application Note: One early adopter of the 400 Series uses the flowmeter to perform leak checking of fire-fighting equipment. A leading designer and manufacturer of self-contained breathing apparatus that is utilized by fire and rescue organizations worldwide requires accuracy, fast response, and reliability. The HFM-I-405 (1,500 SLM full scale) is one of the Teledyne Hastings mass flowmeters used to perform leak testing and conduct minimum and maximum flow tests for every breathing pack manufactured.

The end-user has designed special testing cells that have model heads to which the breathing masks are mounted. The Teledyne Hastings mass flowmeters then monitor leakage from the apparatus and monitor the flow delivered to the user for minimum and maximum rates of pressure. Flowrates vary depending on the actual style of breathing pack being tested.

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VPFlowScope Mass Flow, Temperature, & Pressure Measurement Instrument
By VPInstruments
www.vpinstruments.com

VPInstruments’ VPFlowScope, measures mass flow, temperature, and pressure simultaneously. The bright blue LCD display provides real-time information on all three parameters. Another important property of the VPFlowScope is its built-in data logger with 500,000 points. This function enables users to store data for a certain period of time. The PC software allows users to follow measurements in real-time, process data, and print reports.

Features & benefits:
• All-in-one device. Measuring the most important parameters at once, making extra sensors and cables redundant.
• Ease-of-use. Information on the parameters is available to the user at all times. The VPFlowScope registers data by merely pushing the record button and transfers data to your PC within seconds.
• Modular concept. Thereby enhancing user’s flexibility. The sensor and display communicate via a digital protocol, so they can be exchanged without re-calibration.
• Easy to install. The VPFlowScope is installed in the pipe and one can start measuring immediately. There are no difficult programs to be followed.
• Cost savings. By implementing the VPFlowScope in a compressed-air system, everyone can get insight on their energy consumption and leakage. Energy savings in compressed-air systems can range from 15 percent to 50 percent.

Testimonial: Geveke Energy Services offers compressed-air audits to identify opportunities for energy savings. The company advises clients how they can realize savings and how they can improve the efficiency of their compressed-air system.

“Every time we perform an air audit, we make use of the VPFlowScope. We have had this instrument for one year now, and we use it almost every week,” said Ab Soekhoe, general manager of Geveke Energy Services.

“We use the VPFlowScope because we can measure mass flow, pressure, and temperature with one instrument. With other flowmeters, we needed separate pressure and temperature sensors. We also encountered trouble with synchronizing different data loggers. The VPFlowScope was the ideal solution for these problems.”

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VOTING IS NOW CLOSED!!!
THANKS FOR SUPPORTING THE 2008 INNOVATION AWARDS PROGRAM.