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

September 2006

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2006 Innovation Awards
Flow Control Honors the Year’s Most Outstanding Technologies

The following technologies are the winners of the 2006 Flow Control Innovation Awards competition. Nominations for this year’s Innovation Awards program were presented to Flow Control readers for open voting in June. We received nearly 1,000 votes for the Innovation Awards from a wide variety of fluid handling-related backgrounds, including academia, consulting and services, government, manufacturing, utilities, and others. If you have questions about any of the winning technologies, please contact FlowControl@GrandViewMedia.com. Also, please check out the October issue, as we will be providing short case studies on the winning products to give you a feel for some real-world applications of these technologies.

Model 7510+ Multipath Transit-Time Flowmeter
By Accusonic Technologies
www.accusonic.com

Accusonic’s Model 7510 multipath, transit-time flowmeter measures flow in environments ranging from open channel to partially full and full pipe. Pipe or channel sizes can be as great as 300 feet or as small as six inches. The 7510 can measure up to a maximum of four different pipes and/or channels in one flowmeter console. In addition, the meter provides an average section temperature measurement. Flowrate accuracy is +/- 0.5 percent to 1.0 percent for full pipes and +/- 1.0 percent to 2.0 percent for partially full pipes and open channels. Temperature accuracy is
+/- 0.1 F.

what the voters said:
• “The 7510 is very versatile with good accuracies and is able to measure
partially full pipes.”
• “Looks like a great meter for open-channel flow!”
• “The capability to measure flow in a filled or partially filled pipe is nice.”

IntelliServe 2.5 Flow Monitoring System
By ADS Environmental Services
www.adsenv.com

ADS Environmental Services’ IntelliServe 2.5 is a Web-based system that automates the integration of flow data and rain data to differentiate between wet and dry weather overflows at combined sewer flow structures. This provides municipalities with a means of distinguishing between permitted wet-weather overflows and the not-permitted dry-weather overflows. In addition, the IntelliServe software delivers the flow data required to accurately report to the EPA the quantity of all overflows.

what the voters said:
•“Intelliserve is one of a kind that nobody else has developed before. Web-based flow monitoring is a good tool to manage and maintain a medium to large sewer system.”
• “It provides information which previously had to be correlated manually for EPA reporting.”
• “The IntelliServe product is the first of its kind and is revolutionary in the field of preventing sewer overflows into receiving waters. Could be the environmental breakthrough of the decade.”

Type 8041 Electromagnetic Flow Transmitter
By Burkert Fluid Control Systems
www.burkert.com

Burkert’s Type 8041 magnetic flow transmitter is a low-cost, blind magmeter with four to 20 mA and frequency and relay outputs all in a single, standard, off-the-shelf unit. The SS finger and PEEK seal material allow for high-pressure (230 PSI) and high-temperature (302 F) applications. It is a good fit for higher temperature/pressure applications across a wide range of engineered system scenarios, with a -4 F to 302 F medium temperature range and 233 PSI maximum fluid pressure capability (with a brass or stainless steel fitting). The unit is designed to operate as both a transmitter and/or an on-off control device.

what the voters said:
• “Best value for the cost.”
• “It’s a low-cost sensor that can be used for higher temperature and with higher pressure.”
• “A low-cost solution for a full-bore magmeter!”

1010 Ultrasonic Transit-Time Flowmeter
By Controlotron
www.controlotron.com

Controlotron’s 1010 ultrasonic transit-time flowmeter can provide both high-speed analog and digital pulse output proportional to flowrate. This high-speed flow update rate allows the 1010 meter to be applied in applications previously thought to be outside the capability of ultrasonic meters, such as process control, surge control, and short-volume batch applications.

The 1010 meter overcomes common process control issues by providing as many as 80 flow updates per second via an available four to 20 mA analog output (for control loops), as well as a digital pulse output, which is particularly useful for volume totalization.

what the voters said:
• “The Controlotron ultrasonic meter's Wide Beam technology is impressive for the way the pipe wall acts as an acoustic waveguide and provides an auto-zero function. Many ultrasonics I've used in the past are merely indicators that don't provide for more than +/- 5 percent or worse accuracy. The product is easy to install, and the support given to get the best use from the meter is outstanding.”

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

Dwyer Instruments’ Digihelic II pressure controller combines a differential-pressure gauge, switch, and transmitter with Modbus communications all into a single, compact package. Along with the ability to be used in a myriad of pressure applications, the Digihelic II can be combined with a flow sensor to calculate appropriate velocity and flow readings. The unit comes in a NEMA 4 enclosure designed to meet the performance and aesthetic requirements for cleanroom applications in the pharmaceutical and semiconductor industry. It provides 0.5 percent accuracy on full-scale ranges as low as zero to 1⁄4” w.c. to 100 inches w.c. Bidirectional ranges are also available up to 10 inches w.c. All units can be powered with 120-220 VAC plus 24 VDC.

The Digihelic II has large, easily readable LCD’s that are complemented by additional contrast through the use of white backlighting. Alarms can be programmed for high, low, or high/low and can be automatically or manually reset.

what the voters said:
•    “It addresses the digital era, and it meets my application needs.”
•    “We source these, as well as many other parts, for Hewlett Packard, and have found them to meet or exceed expectations. Speedy delivery is often critical, and Dwyer has always met our needs.”

3095 MultiVariable FOUNDATION Fieldbus Mass Flowmeter
By Emerson Process Management,
Rosemount Division
www.rosemount.com

Rosemount’s 3095 MultiVariable (MV) Foundation fieldbus mass flowmeter is a differential-pressure-based mass flow measurement device. It features patented, realtime, fully compensated mass flow in the form of a mass flow transducer block. This design innovation enables excellent DP-based mass flow accuracy within the Foundation fieldbus architecture.

The system provides mass flow, mass flow totalization, and flow-based diagnostics. Typical multivariable Foundation fieldbus devices are limited to publishing pressure, differential pressure, and temperature on a segment. The 3095 MV delivers high performance at the point of measurement, where it is most needed. The result is reduced variability and better process control.

what the voters said:
• “We feel in Russia that Foundation Fieldbus will start to grow very fast this year, and implementing it into the very popular, comfortable, and accurate 3095MV transmitter provides a simple look into the future of DP flow applications.”

Proline t-mass 65 Thermal Flowmeter
By Endress+Hauser
www.us.endress.com

Endress+Hauser’s Proline t-mass 65 thermal flowmeter is designed for direct measurement of gases without the need for density compensation. T-mass has integrated current input, so pressure from an external pressure transmitter can be included into the measurement to increase the meter’s performance in critical applications.

The flowmeter’s integrated Gas Engine offers users the ability to change the behavior of the meter on different gases in the field. This includes a thermodynamic property calculator for 20 different gases and their mixtures. Users can select and program the pure gas or gas mixture directly on the device. (Users are not limited by factory pre-sets.) Calibration is automatically scaled according to gas composition and process conditions (process pressure and measured temperature).

A new sensor concept features a significantly improved thermal dispersion sensor isolated from external temperature effects by a material with very low thermal conductivity (PEEK).

what the voters said:
• “The special sensor isolation (PEEK) protects it from ambient temperature variation for better accuracies.”
• “The software in the meter allows you to specify the percentage of each gas in the stream, and the meter compensates for the thermal properties of the mixture of gases.”
• “Gas Engine renders the need to calibrate on specific gases unnecessary.”

WaveInjector Transducer Assembly
By Flexim Instruments
www.flexim.com

Flexim Instrument's patented WaveInjector assembly allows flow transducers to send sound signals into a hot pipe wall via optimized metal coupling plates. The plates decouple the transducers thermally from the hot pipe surface. Much like heat sinks, the heat-radiating surfaces of their geometry is several hundred times greater than the heat-conducting surfaces. In this way, a substantial temperature differential between the surface of the pipe and the transducer is obtained. Even when the temperature of the surface of the pipe exceeds 750 F, the temperature of the transducer is far below the maximum temperature of standard flow transducers. As a result, high-temperature measurements can be performed with Flexim's standard ultrasonic flow transducers.

The WaveInjector system supports accuracy of +/- 1.0 percent of rate, repeatability of +/- 0.15 percent, dynamic range of +/- 40 ft/sec (12 m/sec), unlimited pressure range, a temperature range of -140 F to 752 F (-100 C to 400 C) and pipe sizes of 1.5 inch OD and greater.

what the voters said:
• “The Flexim device is remarkable, and if I had to pick, it would be the overall winner.”
• “Noncontact, nonintrusive feature is very cool.”
• “The Flexim WaveInjector Transducer is innovative because the sensors are the first link in the flow measurement chain. The accuracy of the sensors is critical to the accuracy of the overall operation.”

DigitalFlow ISX878 Intrinsically Safe Ultrasonic Transmitter
By GE Sensing
www.gesensing.com

GE Sensing’s DigitalFlow ISX878 is an intrinsically safe ultrasonic transmitter that requires just 60 mW for operation. With its low power consumption, the loop-powered ISX878 brings the shutdown-free installation and low maintenance of clamp-on flowmetering to hazardous areas. The ISX878 eliminates the need for heavy explosion-proof junction boxes and conduit. Its reduced power usage and intrinsically safe loop-power design save substantial costs over typical hazardous-area installations. The ISX878 uses an available twisted pair of instrument cables, fed through a safety barrier, to power the unit. The ISX878 is Baseefa, ATEX, and IECEx certified, with FM and CSA certifications pending.

Accuracies of +/- 1 percent to 2 percent of reading are typical for pipe inner diameters greater than six inches and +/- 2 percent to 5 percent for pipe inner diameters less than six inches. Operating temperatures range from -4 F to 140 F.

what the voters said:
• “It’s a two-wire, clamp-on liquid flowmeter with all approvals that really works.”
• “The meter is unique both for its loop powering and intrinsically safe use in Div. 1.”
• “It allows users to make flow measurements on existing pipes in electrical classified hazardous areas. This low-power meter opens up applications in process plants.”

Coriolis 1700 & 2700 Transmitters with ELITE F-Series & T-Series Sensors
By Micro Motion
www.micromotion.com

Micro Motion’s Coriolis meters are certified to the SIL-3 level (products and processes). This certification applies to both the Micro Motion primary (sensor) and secondary (transmitter) elements. The meters eliminate many of the traditional sources of error in safety loops — design, specification, installation, or maintenance of the primary (e.g., traditional orifice with impulse lines).

The smart Safety Instrumented System (SIS) from Emerson Process Management, an extension of the PlantWeb digital plant architecture, is now further enhanced with TÜV certification of Micro Motion SIS Coriolis meters. This certification allows users to boost plant availability by using Micro Motion Coriolis flow and density measurement products in Safety Instrumented Systems in up to SIL-3 loops, per IEC 61508. As such, plant designers can now simplify new SIS designs and compliance management. Micro Motion SIS Coriolis meters integrate into the comprehensive Emerson solution for SIS that includes the DeltaV SIS system with smart logic solvers, final elements such as Fisher FIELDVUE SIS digital valve controllers, and Rosemount SIS pressure and temperature transmitters.

what the voters said:
• “I have used this flowmeter, and it was capable of a high precision measurement of a very thick fluid for a small totalized flow. We were able to then control the input of the fluid based on the output. It worked great for a very thick fluid.”
• “Micro Motion's Coriolis meters are certified to the SIL-3. This allows users to apply these flowmeters in safety systems with confidence and data to verify their applicability.”
• “This flowmeter is one of the most dependable meters I have seen. We use it to measure six fuel/oil flows to three LK burners and it is so reliable. Another advantage that I have seen with the meter is that you can get a high-temperature version. We ordered this feature so we would be able to steam it out. Good product and would recommend it for exact flow measurements.”

BASIC+ 400 Series Thermal Dispersion Flow/Level Switch
By Kayden Instruments
www.kayden.com

Kayden Instruments’ BASIC+ 400 Series thermal-dispersion switch performs in flow, level, and interface level applications. It is suitable for air, gases, liquids, or slurries and provides a constant visual display of the process (flow or level) on the front panel display. The switch accepts either AC or DC power and features true temperature compensation and self-diagnostic functions. The switch is built around electronics modules that are completely field-replaceable and interchangeable without removing the sensors from the process. It provides a lower-cost alternative for simple flow/no-flow and wet/dry level applications.

Built to withstand the Canadian Oil Sands, Kayden switches offer durability and instrument life. A patented sensor design supports all-welded, thick-steel construction with sensitivity and repeatability. A full-function display and front-panel control buttons provide easy setup for flow or level and for gas or liquids. True temperature compensation is provided by a microprocessor, which eliminates the need for adjustments due to changing ambient conditions.

what the voters said:
• “It provides a lower-cost alternative for simple flow/no-flow and wet/dry level applications. It is easy to operate.”
• “The product works for what it says and the technology is far more advanced than anything in its category.”
• “True temperature compensation and self-diagnostic functions.”

Vent Master Venting System
Parker Instrumentation
www.parker.com/instrumentation

Parker Instrumentation’s Vent Master is a turnkey solution for venting samples from process analyzers into a plant’s flare disposal or return system. It is comprised of regulators, gauges, a rotometer, and an eductor assembled in a compact panel. A separate sensitive pressure regulator is mounted to the vent header and connected to Vent Master. The product creates a constant pressure environment in the vent header to keep process analyzers operating at their maximum accuracy. Vent Master eliminates the need to vent to atmosphere and resolves analyzer accuracy issues commonly associated with alternative disposal techniques.

what the voters said:
• “I teach analytical instruments, and the Vent Master is an excellent solution to a nasty problem”

SIG/SRG Thermal Mass Flowmeters
By Sage Metering
www.sagemetering.com

Sage Metering’s SIG and SRG Series general-purpose thermal mass flowmeters for gases are available with up to four independent calibrations (four gases or gas mixes; four pipe configurations; or four different sensitivities, allowing rangeability as high as 2000-to-one). The meters can also be switched in the field in seconds via a touch-panel keypad shortcut (channel A, B, C, or D), which can be manipulated with the cover in place to maintain the NEMA 4 integrity of the enclosure. The shortcut can also be manipulated from a laptop computer by accessing the free Sage software, Sage VIP, if desired. The new switching feature inherent to the SIG and SRG flowmeters allows each channel to have dedicated accuracy.

what the voters said:
• “The unit has multiple gas calibrations in a single meter.”
• “Four independent calibration capability with 2000-to-one range and four-channel switching capability WITHOUT removing the cover along with remote access (albeit through proprietary software) … What more could you ask for!?
• “Four independent flow channels! That allows for huge turndown and different gas make-ups.”
• “The ease of switching is incredible. Reliable and accurate.”

Max-Trak Model 180 Flow Controller
By Sierra Instruments
www.sierrainstruments.com

Sierra Instruments’ Max-Trak Model 180 industrial flow controller is a NEMA 6 (IP67)-compliant gas mass instrument. Made for washdown environments, the Max-Trak features a fully enclosed valve design to drastically minimize leak-in paths for maximum protection. The Max-Trak Model 180 is resistant to leaking in pharmaceutical manufacturing washdown applications. The flow controller can be washed repeatedly with no penetration of water to the sensitive electronics inside. The instrument also measures and controls gas mass flowrates from zero to 200 SLPM (up to 400 SLPM upon request) in a flow body a little over five inches long. It offers accuracy of +/- 1 percent of full scale, with repeatability of +/- 0.2 percent. Max-Trak also includes Sierra’s patented Dial-A-Gas technology, which allows users to select from up to 10 gases in one instrument.

what the voters said:
• “I think the Max-Trak will be a much simpler item for us to install in future applications with the high turndown ratio, the small size, and multi-gas capability. The washdown feature is not critical for us, but it will aid our efforts to keep the lab clean of contaminants.”
• “Having the various gases pre-programmed in greatly reduces installation time and reduces programming errors caused by using the wrong variables.”
• “We have been looking into mass flow controllers for some time now and Sierra has consistently impressed us with new innovative products and fresh thinking.”

Pro-Flo X Air-Distribution System
By Wilden Pump & Engineering
www.wildenpump.com

Wilden Pump’s Pro-Flo X air-distribution system (ADS) is based on a patent-pending EMS (efficiency-management system), which allows each pump to be customized specifically for the actual operational parameters, regardless of application demands and pump size.

The Pro-Flo X ADS and its EMS technology are simple and easy to use. With the turn of an integrated control dial, the pump user selects the desired efficiency point and flowrate that best meets the application need. The results are higher performance, lower operational costs, and performance flexibility. The EMS provides the option for pump users to control flowrates, air consumption, and energy efficiencies. The EMS is intelligently designed into the ADS architecture.

what the voters said:
• “The idea to be able to adjust your pump in the field is great and very innovative.”
• “A pneumatic pump that allows you to control the efficiency at which it operates is unique. Users of this kind of pump will benefit form the increased air-consumption efficiency.”
• “About time somebody incorporated a flow control system into the air-distribution system of an air-operated diaphragm pump.”
• “Having an integral control valve is a significant addition to air motor technology.”

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