This year’s Innovation Awards program received more than 3,500 votes for more than 45 nominees, which included some truly innovative fluid handling technologies. The following 12 products are this year’s winners. We will be publishing case studies on each winning product in the October issue to give you a feel for how they are being used in real-world application environments.
Product: FSM Electromagnetic Flowmeter
Release Date: April 2004
Company Name: ABB
Notebook: The FSM4000 electromagnetic flowmeter employs advanced digital signal processors, enabling better accuracy than typically pulsed DC electromagnetic flowmeters. The meter is well suited for pulp & paper and mining applications with high solid content, low conductivity, pulsating flows, and/or noisy process conditions. Featuring AC magnetic field excitation and digital signal processing, the FSM4000 magmeter delivers accuracy of +/- 0.5 percent of rate, which is unique for a system with such a fast response time. With its AC excitation, the FSM4000 measures 100 percent of the useful signal, leaving no measurement signal unprocessed. The FSM4000 also employs a diagnostic coil to actively adjust the zero and eliminate any line noise. This innovative signal gain provides more information for processing and a high signal-to-noise ratio.
Customer References: P.H. Glatfelter Co. of Spring Grove, Pa. is a North American leader in the manufacture of publishing papers and one of the world leaders in tea bag papers. The FSM4000 is measuring on the company’s basis weight line in series with a dual frequency DC meter. The dual frequency meter is operating at a 15 percent variation with 32 seconds of dampening. The FSM4000 is operating with only 1 percent variation at three seconds of dampening. This tighter variation allows Glatfelter to have tighter control of its process, enabling a significant savings in pulp stock.
Product: Permovial Universal Tank Mixing System
Release Date: June 2004
Company Name: BIF
Notebook: The Permovial Universal Tank Mixing System is a patented potable water-mixing unit that uses the laws of physics to provide total, thorough mixing of water in storage tanks. Providing peak quality water is a critical issue for today’s public water utilities. The Permovial system is the first system in the world to utilize the laws of physics and fluid dynamics to properly and adequately mix water in elevated and ground storage tanks. Water is mixed both on the fill and the draw cycle of tank operation without the input of any external energy. The system is driven by the reduction of water pressure as the water flows into the storage tank.
Customer Reference: “Without question, the addition of the mixing system in potable waters storage tanks significantly improves quality.” — Jose Hernandez, Cleveland Public Water
Product: Digihelic Pressure Controller
Release Date: August 2004
Company Name: Dwyer Instruments
Notebook: The Digihelic pressure controller combines a differential pressure gauge, switch, and transmitter with Modbus communications all into one single, compact package. Along with the ability to be used in a myriad of pressure applications, the Digihelic can be combined with a flow sensor to calculate appropriate velocity and flow readings. The unit comes in a compact 1/8 DIN ABS plastic housing with NEMA 4x front face. The units possess a 0.5 percent accuracy on full-scale ranges as low as 0-.25″ 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 has bright LED”s on the front face to indicate when an alarm or setpoint relay has been activated. Alarms can be programmed for high, low, or high/low and can be automatically or manually reset. The unit is field-programmable with five simple menus: a security menu for locking out certain aspects of the controller; a control menu for selecting the engineering units and whether the control is operating in pressure, velocity, or flow modes; an output menu that allows selection of single setpoint control, dual setpoint control or setpoint/alarm control modes; a display menu that allows the user to select the digital dampening required for the application; and an advanced menu that allows the user to recalibrate the unit easily in the field.
Product: 3051S Ultra for Flow Flowmeter
Release Date: January 2004
Company Name: Emerson Process Management, Rosemount
Notebook: The Rosemount 3051S Ultra for Flow takes a unique approach in the design and manufacture of transmitters to optimize performance over wide flow turndowns. Performance with 3051S Ultra for Flow is specified as a percent of reading, versus the traditional percent of span used by virtually every other differential pressure flow transmitter. As a result, the device can support up to 14-to-1 flow turndown with better than a 0.5 percent accuracy. Traditionally, orifice-based flowmeters have only been able to maintain accuracy over a much smaller 3-to-1 operating window. The SuperModule, the foundation of the 3051S transmitter, is designed with enhanced functionality that supports scalable performance. The transmitter’s hermetic, all-welded stainless steel housing allows the device to be used in the harshest environments. Coplanar process isolators allow the sensor to float freely, eliminating the effects of installation-induced errors. With the 3051S, each transmitter is manufactured according to the performance requirements of its future application. The device eliminates the need to stack transmitters for flow applications, resulting in better performance and lower installation costs.
Product: Proline Promass F 10-Inch Sensor
Release Date: November 2004
Company Name: Endress+Hauser
Notebook: The PROline Promass F 10-inch sensor is a Coriolis system designed to provide direct flow measurement in applications where other types of instruments have traditionally been used. PROline Promass F can be used in place of turbine meters, differential pressure meters, or multipath ultrasonic meters. Traditionally, Coriolis meters with 10-inch sensors have been extremely large and heavy, as well as difficult and expensive to install. PROline Promass 83 F is smaller — approximately 72.3 inches in length (150# flanges) at a weight of 882 lbs, which is roughly 40 percent less than competitive Coriolis meters. Accuracy is +/- 0.1 percent of mass flow; +/- 0.005 g/cc density (field calibration). Fluid temperature range is -58 F to 392 F, and ambient temperature is -4 F to 140 F. The meter is a fully welded stainless steel design, available in six-inch, eight-inch, or 12-inch process connections.
Product: TransPort PT878GC Gas Flowmeter
Release Date: April 2004
Company Name: GE Infrastructure Sensing
Notebook: TheTransPort PT878GC is a clamp-on, portable ultrasonic flowmeter designed for gas applications. The technology has been used successfully in hundreds of clamp-on gas flow applications since it’s introduction. Several customers customized their own carts and Pelican-type cases with 24 VDC batteries in order to be able to use the meter in remote locations in a semi-portable fashion. The PT878GC provides a kitted system designed for portable clamp-on gas measurement applications. The electronics platform is completely portable, battery-operated, and provides data-logging capability so that user’s can perform flow survey work. A variety of clamping fixture are available, supporting pipe sizes from ¾” to 24 inches.
Customer Reference: “I was impressed at how quickly they could set the meter up and get reliable readings. We compared a PT878GC to a natural gas custody-transfer meter and tracked it within 2 percent for two hours.” — Brad Dixon, KinderMorgan
Product: CLASSIC Flow, Level, and Temperature Switch
Release Date: March 2004
Company Name: Kayden Instruments
Notebook: First introduced in 1998, the CLASSIC was upgraded in 2004 to include many new features. The CLASSIC contains no jumpers or dip-switches. All user options are set from the switch’s front panel or remotely via Modbus. The input power is universal with no switches to select between 12/24 VDC & 115/230 VAC. Via Modbus, the user can lock the front panel for compliance with SILs (safety integration levels). The CLASSIC performs well in flow, level, interface, and temperature applications with air, gases, liquids, and slurries. With six built in timers, applications can be automated without a PLC. Timers and external circuits continually monitor the microprocessor and associated electronics. The microprocessor also runs continuous diagnostics on the sensor components and wiring. These features prevent any software or hardware failures from going undetected. The CLASSIC, unlike conventional flow switches, features a 4-20 mA current loop output, which is configurable to represent the thermal signal or the actual process temperature.
Customer Reference: “Encana Gas Storage uses the Kayden CLASSIC flow switches in many applications. The most widely used application for this switch is on our flare stacks for flare ignition purposes and for early warning that a PSV or rupture disc has failed. In both cases, the Kayden switches have proven their worth and paid for themselves 100 times over. With the large volumes of gas we are dealing with, the smallest indication when we have a PSV lifting pays for these switches. Good product, and we will continue to incorporate these in any future designs.” — Chris Sas, EIC Coordinator , Encana AECO Hub & Countess Gas Storage
Product: OPTIWAVE/OPTIFLEX Radar Level Gauge
Release Date: October 2005
Company Name: KROHNE
Notebook: KROHNE’s OPTIWAVE (noncontact radar) and OPTIFLEX (contacting guided-wave radar) feature high-speed signal processing and filtering to increase both the bandwidth and dynamics, enabling higher precision, greater reliability, and simplified installation. Based on the frequency modulated continuous wave (FMCW) signal generation and evaluation technique, the OPTIWAVE/OPTIFLEX products allow for more accurate, reliable, and continuous level measurement with higher resolution and greater mapping and suppression capability than traditional pulse-based systems. The systems offer operating frequency of 24–26 GHz. Accuracy is +/- 0.12”, with a resolution of 0.04”.
Customer Reference: “The ingenious part of the OPTIFLEX is its innovative and intelligent diagnostics capabilities. KROHNE offers a level of reliability in operation that has never been experienced anywhere before.” Dr. Armin Brucker, BASF.
Product: F300 Mass & Volume Flow Sensor
Release Date: July 2004
Company Name: Micro Motion, Emerson Process Management
Notebook: The F300 features a balanced design to provide stability for larger and more compact Coriolis flow and density meters. A patent-pending technology, the sensor offers a compact and durable design, making it a good fit for larger pipe sizes in harsh environments where space and ruggedness are essential. The systems high flow capacity is 10,000 lb/min.
Product: Opti-Con Controller
Release Date: To Come
Company Name: Philadelphia Mixing Solutions
Notebook: The Opti-Con controller uses real-time data transmitted through an array of sensors to control the equipment dedicated to biologically treat wastewater. Flow variations are known as a diurnal curve. It represents the difference in operational flow during a period of time. The Opti-Con ensures the plant operates at the optimal efficiency to handle flow variations, biological treatment, and energy consumption. This control leads to improved solids settleability, reduced chemical utilization, and improved effluent quality. Control of the Opti-Con is achieved through a secure Ethernet connection that provides remote access. All units can be linked to one SCADA location. The Opti-Con can be configured to all aeration systems. Recording real-time characteristics enables the Opti-Con to make flow control decisions based on true conditions.
Product: Pivotrol Pump
Release Date: November 2004
Company Name: Spirax Sarco
Notebook: The Pivotrol Pump features Spirax Sarco’s PowerPivot technology, which replaces bearing surfaces with pivots to extend the service life of a mechanical pump. The pump is made of stainless steel components and carbide pivots. A fully patented design, the pump virtually eliminates friction and wear by replacing large numbers of bearing surfaces with a few pivot points. Friction within the mechanism has been reduced to a negligible amount, thus extending the service life of each mechanism. Three and five-year warranties are available for three million and five million cycles.
Product: ADMAG AXF Magnetic Flowmeter
Release Date: August 2004
Company Name: Yokogawa
Notebook: The ADMAG AXF magnetic flowmeter features electrode coating diagnostics to ensure the accuracy of the meter isn’t impeded by build-up of material on the electrode, a situation that requires periodic maintenance. With conventional magmeters, the maintenance schedule is arrived at based on simple experience and observation. With the new coating diagnostic function of the ADMAG AXF it is possible to monitor the status of the electrodes in real time. The coating level can be judged by measuring the resistance between the electrodes and the earth rings. A small, rectangular current pulse is fed from the electrode to the earth ring in order to measure the resistance using Ohm’s law. The pulse frequency is synchronized with even multiples of the flow signals’ frequencies. When the flow signals are operated, the pulse frequency is cancelled out and thus does not influence the operated computation outputs. Conversely, when the coating diagnosis signals are operated, the flow signals are cancelled out with no influence on the diagnosis results. This kind of signal processing makes electrode coating diagnosis possible even during flow measurement. The severity of the coating is judged in four levels based on pre-defined values. Level 3 corresponds to a warning and a status output signal can be generated. When the coating level is judged to be level 4, an alarm output can also be set. Although the coating criterion levels are preset to reference values at the factory, they can be changed by users depending on their application.