January 2014 PDF

How Reliability Can Learn from Safety Strategic Flow Calibration Ultrasonic Gas Measurement
SOLUTIONS for FLUID MOVEMENT,

MEASUREMENT & CONTAINMENT
Water Hammer
PREVENTION
Using Check Valves to Protect Against Harmful
Process Conditions in Pipeline Applications
JANUARY 2014 Vol. XX, No. 1

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contents
Swing-Check
january 2014 | Vol. XX, No. 1
Standard
Dual Disc
Check Valve
61
18
Vr Reverse Velocity (m/s)
features
DUO-CHEK II
18
NOZ-CHEK
-0-0-
dv/dt Deceleration (m/s2)
22
61
61
28
Addressing the Big Bang

By Gobind Jhiani, P.Eng., B.Sc., C.Eng.
In an oil pipeline, water hammer (pressure surges) occurs from
sudden events, such as a valve closure or a pump trip, often
triggered by an emergency shutdown (ESD). The moving fluid
in the pipeline acts much like a train when it hits an obstacle;
that is, each car slamming into the one ahead causing multiple
water hammers.
22
Flow Calibration Considerations
28
Turnkey Natural Gas

Measurement
34
GUEST COLUMN: A Case for

Fluid Power Certification
By Ben Kelzers & Kyle Shipps

Failure to calibrate flowmeters can negatively impact performance, while calibrating too frequently can result in excessive
costs without providing any benefits. So, the question is, how
do you determine if calibration is needed and what the frequency should be?
By Mehmet Duzen
BOTAS, the state-owned oil & gas company in Turkey, recently
installed a natural gas pipeline allocation system at its natural
gas compressor station at ayirli, a town in the Erzincan Province of Eastern Turkey. The system included a 42-inch ultrasonic
flowmeter, one of the largest in the world, as well as supporting
instrumentation from Emerson Daniel Measurement and Control.
By Marti Wendel
The fluid power industry is currently in need of technical professionals. So where are all the qualified job applicants? Maybe supply
and demand isnt broken, but it might have a glitch or two.
Flow Control (ISSN #1081-7107) is published 12 times a year

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Flow Control Magazine
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36
contents continued
columns
6
VIEWPOINT
the road ahead
16 APPLICATIONS CORNER
success at last! specifying a coriolis mass
flowmeter for gas service
36 PUMP GUY
what reliability can learn from safety
40 AUTOMATION FILE
rockwell automation fair recap
departments
42 WHY you need to know about ipv6
On the Cover: Images courtesy of ThinkStock.
Annual Fa
ctory
Calibrat o
i n
NEWS & NOTES

is steam a reliable measurement?; isa100 spec
enters final phase of iec
approval; readers respond
to the pump guys musings
on the three stooges
Say goodbye
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factory
CLOSE
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w w w . f o x t h e r m a l i n s t r u m e n t s . c o m
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4 | January 2014
Dynamic testing to
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FMC Technologies accredited Flow Research and Test Center puts every meter
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VIEWPOINT
The Road Ahead
G R A N D
GV
V I E W
M E D I A
G R O U P
s we kick off the 2014 calendar year, one of

the key lessons that sticks with me from
recent years past is that the road ahead is shorter
than it used to be. The modern age of technology
has vastly changed the world we live and work in,
and the pace of this change is feverish.
The
cellphone
is the obvious example to turn to when considering how
fast technology is changing the dynamic.
Admittedly, I was one of those curmudgeons who held onto his flip phone for
longer than most just to make the point
that the smart phone was unnecessary.
But as my emails began to pile up during off hours, I soon found myself with
iPhone in hand, and I cant imagine how
I survived so long without it. Yet the time
before smart phones and email was only
a short while ago.
Industry is historically conservative
and slow to adopt new technology, but
the age of high-tech is now knocking
at industrys door. The changes weve
seen over the past 10 years in the business and consumer segments are now
making their way toward the plant floor.
Buzzwords like mobile, virtualization,
cloud computing, and cybersecurity are
commonplace at todays industrial trade
shows and end-user meetings. And
much like weve seen in the consumer
and business markets over the last decade, I believe the industrial organizations who are able to adapt and assimilate their systems to effectively leverage
high-tech will survive, and those who do
not will fall.

Perhaps the most challenging aspect of
technological change today is that it continues to change and evolve. Take for example the world of publishing; our business
is changing so much and so quickly that we
now enter the product development process
knowing that the content-delivery mechanisms we introduce today will likely be irrelevant in 23 years. For an industry that relied
on the same primary business and delivery
models for 250 years, this pace of change
is, I have to say, hard to keep up with. But
it is the reality of operating in a world led by
high-tech, so were doing our best to turn
the technological changes (challenges) we
face to our advantage.
Having learned the lessons of working in
an industry that has seen its fair share of
change over the past 10 years, my advice
to those working in industry is to not waste
time resisting the changes that the age of
high-tech brings with it. Instead, do your
best metaphorical judo to turn the unavoidable and overpowering force of technology
to your advantage. FC
Thanks for your readership,
Matt Migliore, Director of Content
Matt@GrandViewMedia.com
Did You Know?
EXECUTIVE DIRECTOR OF BUSINESS

DEVELOPMENT
JOHN P. HARRIS | (205) 408-3765
john@grandviewmedia.com
EXECUTIVE DIRECTOR OF CONTENT
MATT MIGLIORE | (610) 828-1711
matt@grandviewmedia.com
MANAGING EDITOR
JAKE MASTROIANNI | (205) 408-3784
jmastroianni@grandviewmedia.com
COLUMNISTS
LARRY BACHUS;
DAVID W. SPITZER; JESSE YODER
ART DIRECTOR
JULIE FLYNN
julie@grandviewmedia.com
MARKETING MANAGER
MARY BETH ROMANO
SUBSCRIPTION & REPRINT REQUESTS:
flowcontrol@halldata.com
Administrative Team
GENERAL MANAGER
BARRY LOVETTE
VICE PRESIDENT OF OPERATIONS
BRENT KIZZIRE
GROUP DIRECTOR OF
CIRCULATION & FULFILLMENT
DELICIA POOLE
CIRCULATION MANAGER
ANNA HICKS
VICE PRESIDENT OF FINANCE
BRAD YOUNGBLOOD
EDITORIAL ADVISORY BOARD
Larry Bachus: Bachus Company Inc.

Gary Cornell: Blacoh Fluid Control
Jeff Jennings: Equilibar LLC
Mitch Johnson: JMS Southeast
Peter Kucmas: Elster Instromet
Jim Lauria: Water Technology Executive
James Matson: GE Measurement & Control
John Merrill, PE: EagleBurgmann Industries
Steve Milford: 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
According to Cisco, the number of devices and

systems connected to the Internet will grow
from 10 billion today to 50 billion in 2020.
6 | January 2014
PUBLISHER
MICHAEL C. CHRISTIAN | (908) 507-5472
mikec@grandviewmedia.com
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THE OUTLOOK | News & Notes
Is Steam a Reliable Measurement

When Calculating the Energy Use
of a Heating System?
By Cleve Nyberg
o calculate energy usage

and loads for a heating system, the question is:
Which side of the system
should we measure to provide the most accurate and
encompassing measurement
results?
The simple answer would be the

steam side, since this is the heating
medium providing the energy to the
point-of-use location. However, when
you start to look at the measurement
technologies available and the difficulties presented in measuring a compressible medium, it becomes questionable if the steam side is, in fact,
the most appropriate measurement
location.
Due to the nature of the steam process you are faced with a very hostile
medium with extremely high temperatures. Youre also working with compressibility/density changes due to
pressure/load variances, and operating
ranges that have extreme variations depending on the time of the year/season.
Combined with available measurement
technologies, you are very limited in
your ability to implement a reliable, accurate measurement solution.
As a general rule, the most accurate and reliable technology available
for this application is a vortex-shedding
flowmeter. Vortex-shedding flowmeters
use a blunt body (called a shedder bar)
inserted into the flow stream to create vortices as the flow passes over/
around the shedder bar. Once vortices
are shed, a pickup or sensing technology detects the vortices and the rate
at which they are sensed is proportion
to velocity.
Depending on the sensing technol8 | January 2014
ogy employed, any particular vortex

meter will have a maximum and minimum velocity range. These ranges will
vary with the technology, but as a rule
of thumb, Vortex meters are very linear
and repeatable to +/-1.0 percent of
rate or reading with a typical ideal meter turndown range of 20-to-1. Also,
keep in mind that at the meters low
velocity pointwhich is Reynolds number dependent on where the medium
(steam) goes from transitional to laminar flowthe shedder bar no longer
sheds vortices. This means the meter
has nothing to measure and, therefore,
goes to zero. That is, unless a fixed
output is configured into the output circuitwhich is more common than not
in some devicesto make the meter
read some value. To make the problem

worse, depending on how the meter
was initially sized for the application
(oversized in most cases), 15 percent
to 50-plus percent of the actual load or
flow could still be passing by the meter,
while the meter has no vortices to enable flow measurement.
Cleve Nyberg has 25 years of process control experience with a strong

background in both analytical and flow
instrumentation. He worked in the field
as an application consultant, product
sales manager, and regional sales
manager for two international instrumentation companies prior to joining
Cadillac Meter, also known as Central
Station Steam Company.
7 Reasons to Use/Not Use Steam as a

Measuring Tool for Energy Usage
Here are some of the factors involved in measuring energy usage from the
steam supply side of the system:
1 Ideally, it makes sense to measure since steam is the heating medium at
the point of use.
2 Due to the nature of steam (gas), it is a very difficult medium to measure
with high reliability, accuracy and turndown.
3 Heating loads can, and do, vary widely with seasonal requirements, making
the flow range extremely large.
4 The most well-suited measurement technology is a vortex flowmeter due
to its high accuracy, linearity, and reliability under the demanding process
conditions.
5 Limitations of the measurement technology (vortex) are the operational
rangeability or turndown, which is velocity dependent.
6 Measurement technology (vortex) is not zero-flow-based; it has a low-flow
cutoff where the meter goes to zero even though flow is still passing through
the meter.
7 Fifteen to 50-plus percent of actual steam flows or load is unmeasured due
to sizing and technology limitations of the flowmeter.
best practices & standards
ISA100 Industrial Wireless Standard Enters Final

Phase of IEC Approval Process
SA-100.11a-2011,
Wireless
Systems for Industrial Automation:
Process
Control
and
Related
Applications, received approval from all
21 participating National Committees
of the International Electrotechnical
Commission (IEC, iec.ch) that voted
on the IEC version in a completed
Committee Draft for Vote (CDV) stage.
The CDV stage is the final stage in
the IEC process in which technical comments may be considered. The standard, expected to be issued in early
2014 for a final IEC approval stage in
which no technical comments may be
submitted, will carry the designation IEC

62734 upon publication.
This follows previous approval of
ISA-100.11a as an ISA and American
National Standard. The latter confirmed
that ISAs open consensus standards
development procedures as accredited
by the American National Standards
Institute (ANSI, ansi.org), which require participation not only of suppliers, but of all key interest categories,
were followed properly in developing
ISA-100.11a. ISAs ANSI-accredited
procedures provide for direct participation and voting by experts from end-user
companies, hoping to ensure consideration of the views and requirements

of those who will actually be deploying
wireless systems in real-world industrial
applications.
Festo Offers Free Resources to Aid OEMs with Safety

Standard Compliance
esto (festo.com), a provider of

industrial automation technology
and training programs, is offering a
range of materials designed to help
OEMs more rapidly and accurately
comply with international safety standards. Documents developed include
the Safety Engineering Guidelines
Pneumatic and Electric Solutions
brochure and the Evaluation and

Assessment of Safety Measures Poster.
Both documents, designed specifically
for OEM safety engineering teams, are
available in downloadable PDF format.
The catalog covers directives and standards, safety functions utilizing product
examples, and training and consulting
options. The use of product examples
in the catalog helps make the directives tangible for the design engineering
team. The poster can be used as a
graphical reference tool for information
on risk assessment criteria, designated
architectures, common cause failures,
mean-time-to-failures, and much more.
The poster covers EN ISO 13849-1 and
IEC 61508, 61511, and 62061.
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January 2014 | 9
trendlines
growing oil & gas industry, the need

to replace aging systems, and new
end-user attitudes toward safety are
driving growth in the worldwide process safety system market, according
to a research report published by ARC
Advisory Group (arcweb.com).
Process safety systems protect
people, equipment, and the environment when unsafe conditions occur in
industrial processes, such as oil refining, petrochemical production, or power
generation. The oil & gas industry is the
largest user of process safety systems,
and the industry has been growing
worldwide due to projects for new un-
conventional resources and large complex offshore projects.

The ARC report forecasts the safety
system market will exceed $3 billion
worldwide in 2017.
Dedicated process safety systems
emerged about 30 years ago, which
creates a replacement market opportunity as older systems have become difficult to support.
ARC research indicates that plant
owner-operators are beginning to adopt
a new attitude toward safety system
investments. The severity of recent accidents and incidents in the process industries, combined with recognition of
PaulFleet/iStockPhoto/ThinkStock
Process Safety Systems Market to Reach $3B by 2017,

Fueled By Oil & Gas
the need for greater operational integrity, has led many end-user companies to
take a broader view of safety and re-visit
their existing processes, procedures,
and systems.
New Series of Studies Focuses On Ultrasonic Flow

Measurement, Featuring Breakout Reports On Inline
and Clamp-On Meters
Total Shipments of All Ultrasonic
low Research Inc. (flow
Ultrasonic flowmeters posresearch.com) has released Flowmeters Worldwide (Millions of Dollars) sess key industry approvals
a series of three studies focused 1000
on the market for ultrasonic flow
Some of the limiting factors cit800
measurement technology worlded for the ultrasonic flowmeter
wide, which it has projected to
market include:
600
eclipse $950 million by 2016.
The inherently conservative
400
The studies include an analysis
nature of users in the process
of the ultrasonic flowmeter market
industries
200
as a whole, as well as individual
The cost of inline ultrasonic
studies focused on the market
flowmeters
0
2011
2012
2013
2014
2015
2016
for clamp-on and inline ultrasonic
Issues surrounding calibraflowmeters, respectively.
tion
Compound Annual Growth Rate (CAGR) = 9.6%
The study for all ultrasonic
gions including North America, Western
flowmeters gives market sizes for
According to Flow Research,
2011, analysis, and forecasts through Europe, Eastern Europe/FSU, Mideast/ clamp-on ultrasonic flowmeters are
2016. It provides in-depth segmenta- Africa, Japan, China, Rest of Asia, and benefitting from some unique features,
tion of the market by various product Latin America.
including:
and geographic categories and provides
Portability allows them to be used
technology analysis, profiles of major Some of the growth factors cited for the
in multiple locations and to measure
suppliers, and market share data. The ultrasonic flowmeter market include:
flow in different pipes.
clamp-on and inline studies provide
Successful user experience serves
Completely nonintrusive, since
projections for each specific technolas a paradigm for the industry
the transducers sit outside the pipe,
ogy segment through 2016, as well as
thus completely eliminating any posMultipath ultrasonic flowmeters
technology-specific analysis and data.
sibility of causing pressure drop or of
are gaining use for custody-transfer
Each study examines geographic redisturbing the flow.
measurement
10 | January 2014
Clamp-on meters are also typically

lower in cost than inline meters since
there is no meter body to pay for.
Likewise, Flow Research says clamp-on
meters face some unique limitations:
Their signal passes through the
pipe wall, attenuating the signal.
The width of the pipe is sometimes
an unknown factor that can have an

impact on measurement accuracy.
The material from which the pipe
wall is made can also have an impact on the ultrasonic signal, thereby
affecting the accuracy and reliability
of the signal.
Clamp-on meters tend not to be
as accurate as inline meters and are
not approved for custody transfer.

Because there is more variability in
the location of clamp-on than inline
meters, they may be more difficult to
install correctly.
For more information on Flow Researchs
ultrasonic flowmeter studies, see www.
flowultrasonic.com.
business briefs
Manufacturing Executives
Mildly Optimistic About Next
12 Months
InterOcean Advisors LLC (ioadvisors.com)
released the results of its inaugural manufacturing survey, which asked C-level
executives to reflect on their experiences
over the past year and to give their opinion on manufacturing activity in the next
12 months. Respondents to the survey
represented all major industries in the
manufacturing sector.
Key findings from the survey include:
Approximately 73 percent of manufacturers surveyed believe revenues will
improve in the next 12 months, with
16.4 percent expecting the increase to
be more than 5 percent.
Only 21 percent cited improved market
conditions or increased demand as the
most significant growth drivers in the
past 12 months. Seventy-six percent
attributed growth to company-led initia-
tives, including the introduction of new

products, entrance into new markets,
M&A activity, operational improvements,
expanded sales efforts, and increases in
capacity.
M&A activity is expected to accelerate,
as almost 40 percent of respondents
expect to acquire a business or division
in the next 12 months, while only 26
percent made an acquisition in the past
12 months.
Water and Municipal Groups

Urge Congress to Repair U.S.
Water infrastructure
The American Water Works Association
(AWWA, awwa.org) and 10 other water
and municipal groups are urging key
members of U.S. Congress to support
legislation to repair critical U.S. water
infrastructure. In letters to U.S. senators and representatives on four decisive
committees, the groups urged support
for the creation of a Water Infrastructure

Finance and Innovation Authority (WIFIA),
a federal loan program that aims to
reduce the cost of water projects for
local communities and consumers.
In May, a model WIFIA program was
passed as part of the Senate Water
Resources Development Act, and draft
WIFIA legislation is being developed in
the U.S. House. WIFIA is expected to be
addressed as House and Senate leaders
develop a final water resources bill.
Invensys Inks SK Innovation

to Multi-Year, Multi-Million
Dollar Process Automation
Software Contract
Invensys (invensys.com), a supplier of
industrial software, systems, and control
equipment, has rendered a multi-year,
multi-million dollar corporate license
to SK innovation (sk.com), an energyfocused firm based in Korea. Under
The Next Generation of Pilot Automation

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Tel: (604) 594 5404 | Fax: (604) 594 8845
Toll Free Fax (Canada & USA): 1 800 663 7266
www.singervalve.com
USA Office
Singer Valve LLC, 1873 Scott Futrell Drive
Charlotte NC, 28208
Tel: (704) 391 5785 | Fax: (704) 391 5768
Toll Free (USA): 1 888 764 7858
January 2014 | 11
terms of the agreement, SK innovation, including its subsidiaries, will use

Invensys SimSci ROMeo software to
optimize and improve the performance
of its refining and petrochemical operations in real time. SK Energy, one of
SK Innovations subsidiaries, is Koreas
largest oil refiner with a capacity for 1.1
million barrels-per-day of crude distillation and operating approximately 4,200
service stations across the country.
Yokogawa Tabbed as Main

Automation Contractor for
Chevron Petrochem Project
Yokogawa Electric Corp. (www.yokogawa.
com) has been selected as the main
automation contractor for Chevron
Phillips Chemical Company LPs USGC
Petrochemicals Project. The project will
include a 1.5 million metric tons/year

(3.3 billion pounds/year) ethane cracker
and two new polyethylene facilities, each
with an annual capacity of 500,000
metric tons (1.1 billion pounds). The
ethane cracker will be built at Chevron
Phillips Chemicals Cedar Bayou plant
in Baytown, Texas, and two polyethylene units will be built at a site in
Old Ocean, Texas near Chevron Phillips
Chemicals Sweeny plant. The USGC
Petrochemicals Project is expected to
commence construction in early 2014
and create approximately 400 long-term
direct jobs and 10,000 engineering and
construction jobs.
Emerson Opens $25M Global

Headquarters for Regulator
Technologies in McKinney,
Texas
Emerson Process Management (www.
emersonprocess.com) opened a new
$25 million facility in McKinney, Texas,
which will serve as the global headquarters for its Regulator Technologies
division. The facility will support design,
testing, and manufacturing of Emerson
pressure regulator and relief valve solutions. The facility features a flow lab
capable of testing regulator products in
extreme conditions, as well as various
materials and environmental laboratories. The new facility is one of several
recent Emerson investments in Texas,
including a $34 million Emerson Industry
Center for Hydrocarbon and Energy and
$30 million Americas headquarters for
Valve Automation Technologies, both in
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Metso to Supply Swedish

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Capping Valves to Automate
Digester System
Stora Enso Fine Papers Nymlla mill in
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the supplier of new capping valves for
its batch digester line 1. In total, Metso
will deliver five Neles PZ-series capping
valves to replace the mills old hydraulic
cappers. As a result of the project, Stora
Enso (storaenso.com) will have an automated solution for its digesters, replacWrite in 10 or Request Info Instantly at www.FlowControlNetwork.com/freeinfo
12 | January 2014
ing old valves and actuators that needed manual assistance

in the chip filling phase with the aim of increasing overall productivity. The Neles PZ valves are designed to improve process
safety, enhance process reliability, and eliminate unscheduled
process downtime.
ABB Deploys Outdoor Wireless Network for

PotashCorp Mining Operation
ABB Tropos Wireless Communication Systems (tropos.com)
has deployed an outdoor wireless communications network
for White Springs Agricultural Chemicals, Inc.s PotashCorp
(potashcorp.com) mining operations in White Springs, Fla.
The ABB Tropos broadband network will transport telemetry
data from mining and process equipment to the facilitys
operations center, with the aim of helping PotashCorpWhite Springs increase efficiency, equipment uptime, and
worker safety. Real-time access to data from the mining pit
is expected to improve operational efficiency and safety at
the mine. In addition, video in the mining pit is expected to
enable more effective analysis of the amount of material
being mined and aid the planning of materials transport
from the pit to the processing plant. The ability to monitor real-time video remotely will also enable managers to
ensure safety protocols are being followed.
FMC Launches Website Focused

On Environmental Remediation &
Contamination Issues
FMC Corporation (fmc.com) launched an environmental
website, environmental.fmc.com, showcasing products from
the companys soil and groundwater remediation and water
treatment businesses, technologies and service model, as
well as providing access to technical resources designed to
help customers solve contamination challenges in the complex environments. The website was built to offer various
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January 2014 | 13
reader feedback
Learning From Your Mistakes
Pumps & Check Valves

Larry,
David,
I enjoy the Applications Corner (see page 14) and Quiz Corner
(see page 48) articles you wrote for Flow Control. I especially like
the ones you write where you describe
things that went wrong. Engineers are
very hesitant to discuss their
Success at Las
t!
mistakes. But people
I
learn more from their
In a Pipe
quiz corner:
Flow Velocity
Typical Liquid
mistakes than from
W
their successes. I may
write an article like that
one day; that is if I ever
Flow Problems?
We Can Help
make a mistake. ;o)
Keep up the good work.
APPLICATIO
NS CORNE R |
Flow Measurement
David W. Spitzer
Specifying a
Coriolis mass
flowmeter for
gas service
n my last four
W. Spitzer
Applica
By David
tions Corner
14, Oct. page
columns (Nov.
14, Sept. page
page
I asked
described the
12, Aug. page
decision process
14), I ing design) one of the chemical enginee
apply a Coriolis
used in the mid-198
rs (who
for
mass flowmet
0s to drop through a piping handbook to calculat also did piper in ammoni
service operatin
e the pressure
fittings. Analysis
a
g at
of the inlet piping
sity and the apprehe a relatively low denrevealed the
nsions about
flowmeter in this
using said
New upstream
application. The
and
mass flowmet
1 Coriolis
er installation
pieces were made downstream spool
created such
large obstruct
a
from concentric
ion to flow that
reduc
the flowmeter
would not pass
pipe
ers
that resembled
(even close to)
the operating flow. The
the convergin
second
and diverging
per ion
installat
meters
5
g
with
C.
a
1.5
mass flowmet the above
sections of a Ventu
Coriolis
second
D. Any ofer installation was barely
meter. The new
A. 1 meter per second
to pass
able
the design flow
spool pieces were ri flowdesign velocity
B. 3 meters per
while operatin
almost double
to reduce the
hat is the typical
g at
designed
the nominal
in a pipe?
pressure drop
operating pressure. Then the
of a liquid flowing
ic.
entering and
turer told me
pragmatmanufac
D is Coriolis
the 1.5
Answer
exiting the flowmof the gas
that
meter was properly
I suggest that
approximately
eter.
sized and should
s
400
mbar (6 PSID)
exhibit pressure
Factor
licatinIgwas
conditio
of pressure drop
likely jumped
fluid velocity
e the
now on
at design should drop across the inlet spool-pi
Commentary
A, B, or C, you
dominat
Additional Comp thatns.can
my own to solve
ece was significa
not have created
selected Answers
if the service
factors
the problem.
nt, but
others? FC
If you already
is incomplete
There are many
surprise) the pressure much of a problem. Howeve
the question
you think of any
r (to my
in pipes. Can
defined.
drop across the
the gun because
huge. Now that
s have not been
outlet spool-pi
water) are design
calculat
Flow
ece was
and fluid propertie with low viscosity (such as
contributor to
to work on a solution ions confirmed the problem
3 meters per
is a regular
Boyes,
, I started
Piping for liquids
.
between 2 and
David W. Spitzer a principal in Spitzer and
New upstream
d to operate at
result when
expert
e and
and downstream
velocities may
typically designe
consulting, and
from concentric
Control magazin
spool pieces were
B). However, lower
ring, seminars,
s for future plant
compipe
ion
enginee
reducers
made
provision
second (Answer
automat
that resembled
and
and diverging
LLC, offering
oversized to include
the converging
sections
for manufacturing
com.
the piping is
d flow.
pieces were designe of a Venturi flowmeter. The
witness services
at spitzerandboyes.
ions where
future increase
and
n
applicat
reached
new
in
be
d
spool
expansio
given
entering and exiting to reduce the pressure drop
panies. He can
ation is often
a high liquid
of the gas
Special consider
the flowmeter.
www.spitzerand
the piping unless
nice touch by
623-1830 or
out and plug
hand, while
installing pressure The piping people added a
Consumer
reached at 845
On the other
solids can drop
gauges upstream
stream of the
David can be
s tab to find his
settling
ed (Answer C).
flowmeter.
and downon the Product
technologies.
velocity is maintain reduce the probability of solids
boyes.com. Click
measurement
The Coriolis mass
may
flow and level
pipe wear.
flowmeter was
higher velocity
that
spool pieces,
Guides to various
also accelerates
installed using
and it worked
may be so high
the new
out, higher velocity
fine. Can you
pressure drop
ions, liquid viscosity
an extremely
guess
was across the
In other applicat
A) may result in
flowmeter at design what the
guessed 400
velocity (Answer
mbar (6 PSID)
flow? If you
AM
even flow at low
STRE
you would be
FLOW
SuccessFinally
drop in the piping.
correct.
! FC
@
high pressure
THINK TANK
| Flow Measurement
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RE
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David W. Spitzer
| Coriolis
FLOWSTREAM
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Y C
Z S A om
N
FC-0114-CB
.1.indd
E Ein
A O
Write
14 or Request
I C E
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G Info
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E A Y
E V .com/freeinfo
EntrolNetwork
T
O F O
DavidSpitze
E A
C rQtrAd
E
16 R| January
S C N
2014
WE KNOW FLOW
!
www.spitzerand
THE PUMP GUY | Pumping Systems
Larry Bachus
Why, generally speaking, you should not place a

check on the suction of your pump
arry,
Thanks for sharing

your knowledge,
Years ago, I read a book about process

valves. The book said check valves
belong in the discharge side of a
centrifugal pump. A centrifugal pump
doesnt generate enough differential to
open a check valve in the suction pipe,
especially if the valve is stuck, or springloaded. Hence, system flow might not
develop. In almost all cases, a centrifugal pump will develop enough pressure
to open a check valve mounted into the
discharge pipe.
I am presently trying to explain this
to some colleagues who insist they can
put a check valve in the suction side of
a process pump. You are the Pump Guy.
What do you say?
or pressure) across the valve.

There are many different types of
check valves. You should read the owners manual of a specific valve to know
how much differential force will open or
close the valve.
A cutaway image of a swing check
valve for three-inch pipe is provided
Three-inch swing check valve
Thanks,
here. The gate is gravity-loaded. The

hinge on the bronze flapper is immediately above the flapper in the closed
position. Gravity holds the flapper
closed. The flapper weighs maybe 6 or
8 ounces. This valve will crack open with
a slight differential force. Without other
energy drain, a medium size centrifugal
process pump can generate enough differential pressure to open and draw flow
through this check valve on the suction
side of the pump. (NOTE: I didnt say
I recommend locating check valves on
the suction side of a pump.)
A check valve with a 1-ton (2,200
lbs. or 1,000 kg) weighted arm holding
the valve shut is also provided here. It
will require some serious differential energy to raise that weight and the gate to
the fully open position. This check valve
will starve a medium-sized process centrifugal pump.
John H., P.E.
Jim Drago, P.E.

Garlock Sealing
Technologies
Flow Control Magazin
.com
ntrolNetwork
at www.FlowCo
Request Info Instantly
Write in 26 or
2014
48 | January
David W. Spitze
r
is a regular contribu
Control magazin
tor to Flow
e and a principa
LLC. Mr. Spitzer
l in Spitzer and
has more than
Boyes,
and has written
35 years of experien
over 10 books
ce
flow measure
and 250 articles
ment, instrume
ntation and process about
Mr. Spitzer can
be reached at
control.
845 623-183
boyes.com. Click
0 or spitzerand
on the Product
s tab to find his
Guides to various
Consumer
flow and level
measurement
technologies.
Flow hoot
>> |Troubles
Problem Flow
David W. Spitzer
Corner
Measurements
| Pipe | Quiz
Flow Velocity >> Assess Billing Flowme
ter
>> Close Plant al ProcessingAccuracy
n: Chemicand Water Balance N N L
I Os
November Solutio
T
>> Improve Flowme
I N A
T
ter AccuracyI O N I R
G L U
V A G
I
T
>> Select
T N O
I C A
F
andI Specify
I
T R
S
I
N
T
Flowme
I O L
I
N N ters
G O D
Y C A
>>O Train
A L
TYour
I
People I O T I O I T C
E N N
I
Im not a pump guy, but I very much enjoyed your

article on check valve application with pumps
(October 2013, page 38).
I recall using a foot valve on a training pump
used to show students how to install mechanical
seals and packing. We drew water out of a water
tank located below
grade and then dismailbag: Considering Check
Valve Location
charged it back into
the tank.
L
PM
12/18/13 9:15
Hello John,
In a process system with pumps and
valves, a check valve permits liquid
flow in only one direction. A check
valve automatically prevents reverse
flow when the liquid in the pipe reverses direction. A check valve is unique
because it doesnt require assistance
(an operator or actuation) to open and
close. The liquids energy actuates the
check valve.
The check valve will open with flow
in the correct direction. The valve will
close with reverse flow. It is a little more
sophisticated than simple flow though.
The valve will open or close with an energy differential (liquid weight, velocity,
Weighted-arm check valve
38 | October 2013
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14 | January 2014
The Pump Guy On The Three Stooges

Larry,
Ive enjoyed your column in Flow Control
magazine for some time, but your
article (Nyuk! Nyuk!) in the September,
2013 (page 36) issue was priceless!
Just so you know, I have no experience
in flow movement as I am the budget
director of a small water utility. But I do
so enjoy your ability to explain difficult
and complex problems in pump operations and maintenance.
Since I am the money guy who
has to pay for the numerous pumps and
their problems at my utility, I have made
it my business to read Flow Control to
better understand what my plant personnel are telling me when good things
go bad. Your expertise and the wonderful way you explain things has helped
me greatly. Your writing style will probably keep me reading long after I retire
in December. Keep up the good work!
I am not prone to writing strange
men such positive letters,

but felt you deserved an
Atta Boy.
THE PUMP GUY | Pumping Systems
Nyuk! Nyuk!
Larry Bachus
How the Pump Guy relates to The Three Stooges
he Three Stooges are a (Pump) Guy Thing. In fact,

they are one of the few things my son and I can enjoy
together. Those old food-throwing scenes and fingers-inthe-eye fights leave us rolling on the floor with uncontrollable laughter.
Thanks,
L. B., Budget Director
Municipal Water & Sewer
Systems
Hello Larry,
you go back and finish college and become an engineer yourself. So while
working full time I went
back to college and finished both my bachelors
and masters degrees and
became an engineer and
worked my way up the
technical ladder to engineer/scientist. My early
hands-on experience provided me an insight and
understanding into the advanced technical issues that the purely book-learned
colleagues usually lacked. Thats probably why we hands-on guys are so
often sought after as experts.
The Stooges are Larry, Moe and

Curlysometimes Shemp and sometimes Joe. They spend their days getting
themselves into, and out of, impossible
situations, much like many working mechanics. Most of the time, even they
didnt know exactly what had happened.
When I watch The Three Stooges on
TV, I remember my days in the Navy and
my two cohorts. My name is Larry, and
my mates were Sooty and Joe. Most of
the things we did back then served to
make me the person I am today in this
Root Cause, Six Sigma world.
The year was 1970. I was a mechanic in the Navy, a lowly Seaman on
a pump-improvement team. We were

called to a third-tier military base. It had
an airstrip for military flights and a few
commercial flights each day because it
was convenient for the locals.
At the time, I really didnt understand
pumps. I thought I did, but I didnt. I
knew about rebuilding pumps.
Sooty was my superior. He was a 3rd
Class Petty Officer. His index finger was
paralyzed into a permanent hook. He
called it Lifers Cramp. It was perfect
for dangling a coffee cup.
Im not sure if Sooty was his real
name. It might have been Suity because when he wasnt in his Navy dun-
During his long and storied career, the Pump Guy has had some Stooge-like moments working on pumps.
36 | September 2013
As a retired engineer/scientist with

40-plus years in the electronics and
semiconductor industry, I really enjoyed
and got a nice chuckle reading your
Nyuk Nyuk article in Flow Control. I too
started out as a technician in industry;
and as a young newlywed I used to complain to my wife about the boneheaded
things I would see the engineers do. One
day she said to me you obviously know
more than these engineers, so why dont
garees, he wore a variety of leisure

suits. But he was a trained boiler technician (meaning he could find the Reset button), so his name might have
been Sooty all the same.
Joe was a university math major
when the military draft caught him in
68. A Navy recruiter told him he would
work with computers if he joined the
NavyJoe believed the recruiter.
Anyway, Sooty, Joe and I were sent
to rebuild a large, old split-case pump
tasked with moving chill-water in the
basement of this military air terminal.
Sooty and Joe had done the initial preparation. Sooty isolated the motor, and Joe
removed the coupling to the pump shaft.
My specialty was disappearing for
long periods. (I read my evaluations.)
So, when I arrived, the electric chain
hoist was in place over the pump. The
hooks were tensioned to the lifting points
on the top half of the pump casing. We
removed the big casing head bolts.
Sooty operated the chain hoist because he was a 3rd Class Petty Officer.
Sooty touched the hoist button. The
pumps top casing should have lifted an
inch, but it only rose slightly. The casing head gasket had vulcanized to both
sides of the casing.
Joe pushed his computer (actually, it
was a screwdriver) into the two halves to
keep them separated. Everything looked
OK. I watched the hoist when Sooty
touched the button again. Another inch
of chain passed through the hoist, but I
didnt detect any further movement of
the top casing.
Joe hit his computer (the screwdriver) with another computer (a hammer) to drive the point between the two
casing halves. He said, Once more
and shell break free. He was so right.
Sooty pressed the button again, and
Thank you for sharing your knowledge

and experience with others.
Regards,
Lonne Mays
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January 2014 | 15
APPLICATIONS CORNER | Flow Measurement
Success at Last!
David W. Spitzer
Specifying a Coriolis mass flowmeter for gas service
I asked one of the chemical engineers (who also did pipn my last four Applications Corner columns (Nov. page
14, Oct. page 14, Sept. page 12, Aug. page 14), I ing design) for a piping handbook to calculate the pressure
described the decision process used in the mid-1980s to drop through fittings. Analysis of the inlet piping revealed the
apply a Coriolis mass flowmeter in ammonia
service operating at a relatively low denNew upstream and downstream spool
sity and the apprehensions about using said
pieces were made from concentric pipe
flowmeter in this application. The 1 Coriolis
mass flowmeter installation created such a
reducers that resembled the converging
large obstruction to flow that the flowmeter
and diverging sections of a Venturi flowwould not pass (even close to) the operating flow. The installation with a 1.5 Coriolis
meter. The new spool pieces were designed
mass flowmeter installation was barely able
to reduce the pressure drop of the gas
to pass the design flow while operating at
entering and exiting the flowmeter.
almost double the nominal operating pressure. Then the manufacturer told me that
the 1.5 Coriolis meter was properly sized and should exhibit pressure drop across the inlet spool-piece was significant, but
approximately 400 mbar (6 PSID) of pressure drop at design should not have created much of a problem. However (to my
surprise) the pressure drop across the outlet spool-piece was
conditions. I was now on my own to solve the problem.
huge. Now that calculations confirmed the problem, I started
to work on a solution.
New upstream and downstream spool pieces were made
from concentric pipe reducers that resembled the converging
and diverging sections of a Venturi flowmeter. The new spool
pieces were designed to reduce the pressure drop of the gas
entering and exiting the flowmeter. The piping people added a
nice touch by installing pressure gauges upstream and downstream of the flowmeter.
The Coriolis mass flowmeter was installed using the new
spool pieces, and it worked fine. Can you guess what the
pressure drop was across the flowmeter at design flow? If you
guessed 400 mbar (6 PSID)you would be correct.
SuccessFinally! FC
Flow Problems?
We Can Help
>>
>>
>>
>>
>>
>>
Troubleshoot Problem Flow Measurements

Assess Billing Flowmeter Accuracy
Close Plant and Water Balances
Improve Flowmeter Accuracy
David W. Spitzer is a regular contributor to Flow

Control magazine and a principal in Spitzer and Boyes,
LLC. Mr. Spitzer has more than 35 years of experience
and has written over 10 books and 250 articles about
flow measurement, instrumentation and process control.
Mr. Spitzer can be reached at 845 623-1830 or spitzerand
boyes.com. Click on the Products tab to find his Consumer
Guides to various flow and level measurement technologies.
Select and Specify Flowmeters

Train Your People
WE KNOW FLOW!
www.spitzerandboyes.com 1.845.623.1830
FLOWSTREAM Find related content @

flowcontrolnetwork.com
David W. Spitzer | Coriolis Flowmeter | Pipe Fitting
| Pressure Drop | Venturi Flowmeter
16 | January 2014
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SYSTEMS DESIGN | Check Valves & Water Hammer
ADDRESSING the
BIG BANG
Prevention strategies for water
hammer in SAGD process pipelines
By Gobind Khiani, P.Eng, M.Eng, B.Sc, C.Eng.
ater Hammer (pressure surge) is a pressure wave

caused by a sudden change in water velocity. The
phrase water hammer originates from the hammering
sound that plumbing makes inside a house when faucets
are turned on or off quickly.
Steam Assisted Gravity Drainage

(SAGD) plants produce steam to inject
into formations to reduce the viscosity of bitumen and increase the flow
beneath thousands of meters.
When an SAGD plant installs the traditional swing check valves, the function
of closing this valve is for disc-to-travel
distance to closure, and during high
volume, process flow becomes greater,
causing surge (water hammer or slam).
Water hammer generated in steam
and condensate recovery systems is
usually classified into two main categories:
Caused by high-speed condensate slamming into piping, etc.
Caused by the sudden condensation of steam, which produces walls
of condensate that crash into each
other.
After injecting steam during the recovery of oil, SAGD plants produce oil,
water (condensate) and sand, silt, as
well as some recycled drilling/production chemicals. This is called recovery
of oil. In an oil pipeline, water hammer
(pressure surges) occurs from sudden
events, such as a valve closure or a
18 | January 2014
A Few Events Typically

Induce Water Hammer:
Pump startup: Startup can cause
a rapid collapse of the void space
downstream from a starting pump.
This generates high pressures.
Swing-Check
Vr Reverse Velocity (m/s)
Why Water Hammer Occurs

in SAGD Process Pipelines
pump trip, often triggered by an emergency shutdown (ESD). The moving fluid
in the pipeline acts much like a train
when it hits an obstacle; that is, each
car slamming into the one ahead causing multiple water hammers.
Pump power failure: This can

cause a pressure upsurge on the suction side and a pressure down-surge
on the discharge side. The downsurge is usually the major problem.
The pressure on the discharge side
reaches vapor pressure, resulting in
vapor column separation.
Valve opening and closing:
Closing a valve at the downstream
end of a pipeline creates a pressure wave that moves back toward
the reservoir. Closing a valve in less
time than it takes for the water
hammer to travel to the end of the
pipeline and back is called Sudden Valve Closure. Sudden valve
closure changes the velocity quickly
and results in a pressure surge. The
pressure surge resulting from a sud-
Standard
Dual Disc
Check Valve
DUO-CHEK II
NOZ-CHEK
-0-0-
dv/dt Deceleration (m/s2)
Various check valve closing effects.

den valve opening is usually not as

excessive.
Improper operation or incorrect
design of surge protection devices: Oversizing the non-slam check
valve or attempting to incorporate
some means of preventing water
hammer when it may not be a problem can do more harm than good.
forming a water hammer analysis when

any of the following conditions exists:
The maximum change of flow velocity in a pipeline exceeds 4 per
second.
The length of pipeline is over 200
meters.
There are fast opening and closing valves in the system, especially
in the case of SAGD plants.
The production is pumped out of

the ground (i.e., SAGD production
starts off with pumps in offsites on
the recovery side).
Choices of Valves?
Industry has invented various preventing
measures on water hammer as follows:
Accumulators
Expansion tanks
What Are the Causes of

Varying Velocity In an SAGD
Plant?
Daily operation of a plant demands a
few checklist action items for production
and performance optimization such as:
Closing a valve
Opening a valve
Rhythmic valve operation
Starting a pump
Stopping a pump
Movement of air pockets
Sudden release of pressure from
piping systems
Sudden halt in flow when pressure has been reduced/lowering
production due to operation safety
requirements
Recombination after fluid pressure-column separation
Restarting a portion of the plant
after a turn-around
Why Is This a Problem?

The resulting water hammer can be up
to 10 times the normal pipeline pressure; and this can cause a pipeline
rupture, blown valve or pump seals,
spillage, and many other problems.
SAGD plant systems are vulnerable
to a situation similar to water hammer,
known as steam hammer. In a steam
system, water hammer most often occurs when some of the steam condenses into water in a horizontal section of
the steam piping. Subsequently, steam
picks up the water, forms a slug, and
hurls it at high velocity into a pipe fitting, creating a loud hammering noise
and greatly stressing the pipe. This condition is usually caused by a poor condensate drainage strategy.
Together, we can solve your toughest

process flow challenges.
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To ensure peace of mind and process reliability, visit us today at
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When to Do a Water
Hammer Analysis?
Consideration should be given to perWrite in 16 or Request Info Instantly at www.FlowControlNetwork.com/freeinfo
January 2014 | 19
SYSTEMS DESIGN | Check Valves & Water Hammer
Temperature (oC)
120
Small hammer
No hammer
100
80
60
Large hammer
40
0
50
100
150
The swing check valve is not closing fast enough, allowing water hammer to slam the disc into the seat. Continued slamming damages the sealing surface, preventing
the valve from sealing fully.
As traditional swing check valves are known for sticking,
when previously installed check valves have internals that
are worn or damaged at the hinges, bushings or seating
surface, nozzle check valves are the best alternative, as
they require no spare parts.
Time (sec)
The signs of excessive swing check slamming include

grout cracking beneath pump and motor pads and base, damage to electrical cable connecting the motor, and increased
vibration caused by induced pump and motor misalignment.
Pressure gauges and switches become abnormally out of
calibration, valve seat surfaces crack, there is excessive piping header displacement, and heat exchanger tube failures
caused by pump cycling activations.
Effects of water hammer
Non-slam check valves

Pressure-relief valves
Surge-relief valve
Control valves
SAGD plant systems are vulnerable to a situation similar to

water hammer, known as steam
hammer. In a steam system, water
hammer most often occurs when
some of the steam condenses
into water in a horizontal section
of the steam piping. Subsequently,
steam picks up the water, forms a
slug, and hurls it at high velocity
into a pipe fitting, creating a loud
hammering noise and greatly
stressing the pipe.
Why the Nozzle Check Valve Is the Best

Valve to Prevent Water Hammer?
Nozzle check valves are clean service valves with high reliability, low maintenance requirements, and relatively low
pressure losses. Two factors that determine non-slam check
valve (surge) valve sizing are:
1 Location and
2 Set point pressure.
These application-sensitive valves are known to eliminate
water hammer and potentially destructive surge pressures,
the latter of which is usually associated with conventional
check valves used with centrifugal compressors when surging.
Essentially, nozzle check valves are check valves that prevent reverse flow. These have an axial disc movement with
Selection Criteria for Check Valves in SAGD

in Alberta
Traditional check valves backflow to shut; they are emergency
backflow preventers typically used around critical equipment.
These rely on flow to open. How much the valve opens is
dependent on the flow condition.
Normally a swing check valve is commonly used in industry, but problems can arise with this type of valve, such as
leakage through its seat due to the following reasons:
The valve was installed in an unsuitable application.
For example, most swing check valves cannot be installed
vertically, with the flow passing from above the valve.
The swing check valve was installed less than 10-pipe
diameters away from an upstream pipe fitting or pump.
This results in turbulent flow, disc chatter, and ultimately
damage to the sealing surface.
20 | January 2014
Swing check valve with external slam retarders for water

hammer prevention.
short stroke and a Venturi-style nozzle, which maximizes flow

impact on the disc and minimizes pressure loss. The valves
have better dynamic response, high reliability, and, most significantly, non-slam operational characteristics.
The function of a non-slam check valve is to close quickly. Non-slam check valves close as fast as 30m/sec; this is
achieved with its aerodynamic design built on the principals

of a jet aircraft.
Why Is it Critical to Ensure the Valve Is

Specified and Installed Correctly?
One should take into consideration when check valves are
located downstream of pump elbows or other sources of
turbulence, and when check valves are located downstream
of the pump or compressor. Nozzle check valves should be
in a system where pressure surges during flow transients
and valve closure produces pressure spikes approaching the
system design pressure.
Essentially, when previously installed check valves have
internals that are worn or damaged at the hinges, bushings or
seating surface, nozzle check valves are the best alternative;
also in positions where check valves are known for sticking.
Gobind Khiani, P.Eng, M.Eng, B.Sc,

C.Eng., is with Fluor Canada Ltd. Mr.
Khiani has spent 20+ years in the energy
and power business and has worked in
three countries (United Kingdom, Dubai
and Canada) with 10-plus years in Western
Canadian Oil and Gas Industry based out
of Calgary, Alberta. He graduated from
Gobind Khiani University of Poona in India and earned his
masters degree in Materials and Mechanical Engineering
from Schulich School of Engineering at University of Calgary,
Alberta, Canada. He is a registered professional engineer in
the provinces of Alberta and Saskatchewan. His specialties
are Mechanical Static Equipment Integrity, Quality, Energy
Asset Management, Greenhouse Gases (Energy Efficiency),
and Facility Engineering Management. Mr. Khiani can be
reached at 403-850-6982 or gobind.khiani@fluor.com.
Connect with Mr. Khiani at ca.linkedin.com/in/gobindkhiani.
www.fluor.com
FLOWSTREAM
Find related content @
flowcontrolnetwork.com ... Search on:
Check Valve | Nozzle | Process Pipeline | Steam |
Water Hammer
A cross section of the nozzle check valve employed to mitigate the occurence of water hammer in process pipelines.
The Benefits of Using Nozzle Check Valves

When properly specified and installed via non-slam check
valves, the water hammer in piping systems can prevent
accidents, damage, and increase equipment life.
Water hammer protection via non-slam check valves often
is one of the last lines of protection for SAGD plant pipelines,
saving the day when all else fails, but only if specified and
installed correctly. FC
Did You Know?
The oil & gas industry will

spend over $10 billion
for valves in 2014, with 85
percent of this total going to
on/off valves, according to
McIlvaine Company.
January 2014 | 21
BEST PRACTICES | Flowmeter Calibration
TO Calibrate or
NOT to Calibrate
Understanding when and why your flowmeters
need to be calibrated
ailure to calibrate flowmeters can negatively impact performance, while calibrating too frequently can result in
excessive costs without providing any benefits. So, the question is, how do you determine if calibration is needed and
what the frequency should be?
In many process plants, flowmeters
are calibrated annually or more frequently simply because thats the way it
was done in the past. New instruments
and technologies, combined with careful planning and study, can allow plants
to calibrate flowmeters at an optimum
frequency, resulting in improved operations and cost savings.
A flowmeter that is not measuring
properly can cause many problems. In
a custody-transfer application involving
crude oil or natural gas, even the smallest error can cost a customer millions
of dollars a year. In a food processing
plant, a similar error can adversely affect the quality and safety of food products, resulting in the costs that go along
with such failures.
Because flow measurements are so
critical to many processes, the industry
standard is to calibrate annually, even
though that might not be necessary.
In many cases, this is done in an attempt to demonstrate to a quality auditor that instruments within the process
are under control. For most companies,
annual calibration is performed as a traditional ritual with no scientific basis behind itother than it being the longest
duration of time they are willing to risk
before finding a potential problem.
In many instances, yearly calibrations are not necessary, as some flow22 | January 2014
meters require calibration only once every three or four years depending on the
process fluid, operation, and criticality.
In other cases, a flowmeter may require
calibration much more frequently, possibly on a monthly basis, to maintain a
safe, efficient, or regulatory compliant
operation. Its also important to realize
that calibration intervals are not always
fixed, meaning that they might fluctuate based on usage or historical performance.
How do you determine when to calibrate a flowmeter? By setting up a calibration plan that follows best practices
for flow calibration.
The Importance of
Instrument Assessment
The first step in a calibration plan is
to perform a plant-wide assessment
of all your instrumentation, including
flowmeters. To do this, you must first
identify and make a list of all the equipment parts and all instrument-related
systems. This list should also include
details such as description, local information, working range and history, and
any other points that provide a better
understanding of the parts function.
The first stage in analyzing this data
is to identify which instruments are critical to the application, the environment,
and operator safety. To start, the Head
By Ben Keizers & Kyle Shipps
of Metrology (Quality) and Head of Maintenanceor similar professionals who

have the most in-depth knowledge of
the process and related instruments
should together determine their knowledge of the process environment, the
condition of the installed instruments,
the type of maintenance work carried
out, and, finally, any limitations imposed
by the plant in terms of servicing.
After this information is compiled, it
is important to start from the finished
productand the tolerance permitted
in relation to its qualityand go back
through the various stages in the production process. At each stage it is important to assess each instrument and
flowmeter in place and ask, Does this
instrument have an impact on the quality of the product (or intermediary product) on process functioning, or operator
safety? The total installed base will determine how frequently to calibrate flowmeters. The next step will be to then set
up a calibration plan depending upon
these factors.
The flowmeter manufacturer may
also work with the Head of Metrology
(Quality) and Head of Maintenance to
determine all the factors to bear in mind
when defining which measuring points
to include and assess the plants installed base. They can also help define
the right calibration plan based upon
your frequency needs.
Prioritize Your Flowmeters

After an installed base audit has been
performed, it is important to categorize
all flowmeters by critical importance.
Flowmeters fall into one of four categoFlow Control Magazine
ries, ranging from critical to noncritical importance.

The first categoryflowmeters critical for the product
are those that affect product quality. We start here, because
these flowmeters have a direct link to company profits, whether it involves measurement of ingredients in food processing,
mixing of chemicals, or custody-transfer applications.
The next categoryflowmeters critical to the process
are those that can upset the overall plant or other processes
(shutting down the entire process) and thus cause inefficiencies and production losses, but have no direct effect on product quality or safety.
4 Categories of Critical Importance

Instruments should be classified according to one of the
four categories of critical importance below:
Instruments critical for the product: Instruments that, if defective, may have a direct impact on
product quality.
Instruments critical for the process/system:
Instruments that, if defective, may have a direct impact on process or system performance, without affecting the quality of the final product, or safety.
Instruments critical for safety/the environment: Instruments that, if defective, may have a direct impact on operator safety, or the environment.
Non-critical instruments: Instruments that, if defective, are thought not to have any impact on product quality, process or system performance, safety, or
the environment.
Flowmeters critical for safety have a direct impact on operator safety, equipment protection, and/or the environment.
These flowmeters do not necessarily have to be extremely
accurate, but they certainly have to work properly and reliably.
Finally, non-critical flowmeters have no impact on product
quality, the overall process, safety, or the environment.
After all flowmeters have been identified and classified into
these four categories, a Maximum Permissible Error (MPE) is
assigned to each device. MPEs define the tolerance for each
function being measured. A critical flowmeter will usually have
a more stringent MPE than a non-critical flowmeter.
If you can show an auditor or other responsible entity
that a non-critical flowmeter has no effect on product quality, safety, or the environment, and its MPE is higher, then
you can claim there is little or no need for periodic calibration. Conversely, critical flowmeters may need to be calibrated
more often than annually to maintain critical product quality,
process operation, or safety.
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PROFESSIONALISM.
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of fluid power professionals
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Hydraulics - Specialist, Technician, Mechanic

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System Designer
THE INTERNATIONAL FLUID POWER SOCIETY

(IFPS) is a non-profit professional individual member
organization devoted exclusively to the promotion and
advancement of Fluid Power Technology.
Call 800-308-6005 or visit www.ifps.org
for more information.
Asset Management Software

Flowmeter data from the audit should be stored in an asset
management, maintenance management, or instrumentation
management program. One of the major advances in recent
years has been the development of instrumentation man-
www.fluidpowerjournal.com
www.fpef.org
January 2014 | 23
| Flowmeter Calibration
FLOW PRACTICES
BEST
UPDATE continued
agement software. These systems provide information such

as spare parts lists, drawings specific to the flowmeter, and
original calibration data and certificates (Figure 1).
All flowmeters are calibrated by each manufacturer prior
to delivery to the customer, and the calibration data is easily
entered into asset management software. Afterward, when a
Figure 1. Flowmeter calibration data stored in an asset

management system.
flowmeter is recalibrated, the devices calibration history is updated and can potentially be automatically loaded via an electronic calibrator connected to the asset management system.
Another recent advance allows access to the information
in an asset management system by mobile devices used by
maintenance personnel (Figure 2). From the field, a technician can call up the calibration history, diagnostic data,
troubleshooting instructions, and other information needed to
properly diagnose a flowmeter problem.
Diagnostic data from each flowmeter can be read by the
automation system and/or by the asset management system.
For example, diagnostic data for a Coriolis flowmeter includes
empty pipe detection, sensor drift, sensor error, electronics
error, inhomogeneous mixture error, ambient and process
temperature errors, and other information. This data can be
used to optimize calibration, to diagnose problems, and to
Figure 2. A technician manages a flowmeters calibration

data via a software system.
24 | January 2014
detect minor issues before they grow into substantial problems.

All flowmeter vendors provide this kind of information in
real time, typically via fieldbuses such as Profibus PA, Foundation Fieldbus, or EtherNet/IP. Depending on the fieldbus,
flowmeters can also provide diagnostic data directly to technicians in the field. EtherNet/IP, for example, lets devices be
polled by a condition monitoring or automation system to determine if there are any diagnostic messages that need to be
sent to maintenance personnel as an alert.
An industrial PC equipped with asset management, maintenance, condition monitoring, or HMI/SCADA software can
access all the real-time data and diagnostic information it
needs directly from the devices.
In many cases, modern flowmeters equipped with advanced diagnostics can determine if a problem exists, and
condition monitoring or other software can inform the maintenance department via an alarm that a particular flowmeter
may be having problems.
Deciding When to Calibrate

Setting up a flow calibration plan for individual instruments
often requires assistance from the flowmeter manufacturer
and a qualified calibration company with industry experience,
as they are best qualified to advise on how often a flowmeter
should be calibrated in a typical installation. The end-user
must then use this advice and apply it based on particular service conditions, functions of the meter, and their experience.
Calibration frequency depends on the Criticality and MPE,
as well as the nature of the product being measured, the
continuity of the process (continuous use or intermittent use),
the need for clean-in-place (CIP) operations, the severity of
process impacts, the type of flowmeter (contact or non-contact), and how easy it is to access and remove the flowmeter
for calibration.
In some cases, it may only be possible to access a flowmeter during a complete process shutdown; in other cases,
a flowmeter might be completely accessible for calibration.
In a new plant, setting the flowmeter calibration frequency
is usually based on expected operational parameters and advice from the flowmeter manufacturer and qualified calibration
team. But in an existing plant, the frequency of calibration
can be based on actual historical experience and previous
documented calibration performance with the flowmeters and
processes that yield better results. Its important to note that
in either case, quality, regulatory, or safety requirements may
dictate a specific calibration interval regardless of the advice
from the flowmeter manufacturer or historical data from previous calibrations.
Once a calibration plan has been in effect for a few years,
the instrument management software takes on a bigger role.
When a calibration is done on a flowmeter, new data is recorded and stored in the data base. This data shows the status of the flowmeter before and after calibration, and it may
very well indicate that the flowmeter does not require calibration as often as expected.
Where to Calibrate?
Depending on the application and the standards involved,
flowmeters can require calibration, proving, and/or verification. For calibration, flowmeters are removed from the process and shipped to a calibration facility (Figure 3).
Paraphrasing the formal definition defined by the International Vocabulary of Metrology (VIM), calibration is the procedure to establish a relationship between the quantity value
given by the flowmeter (i.e., mass flowrate for the unit under
test), and the reference quantity value obtained by a calibration reference (e.g., rig), with its associated measurement
uncertainty.
Accredited calibration labs must meet the requirements
to a maximum of 2 (rig), but larger sizes can be calibrated

in-line with master meters. Accuracy is comparable, but the
results are still traceable to recognized national standards
and the turnaround time is reduced to hours versus days or
weeks. For example, Endress+Hausers on-site flow calibration is accredited in accordance with ISO/IEC 17025.
Figures 4 & 5. A portable flow calibration rig performs onsite flowmeter calibration.
Figure 3. At a certified flow calibration rig, flowmeters are
calibrated to meet applicable standards.
of ISO/IEC 17025 (An International Standard that defines the

quality and technical requirements for calibration laboratories) to ensure traceability to the governing National Metrology
Institute (e.g., NIST, www.nist.gov). Accreditation of a calibration laboratorys proficiency is performed by third-party accrediting bodies like the American Association for Laboratory
Accreditation (A2LA, www.a2la.org), or through the National
Voluntary Laboratory Accreditation Program (NVLAP, www.nist.
gov/nvlap/). Laboratories that have achieved ISO/IEC 17025
A2LA accreditation have published defined Scopes of Accreditation, which illustrates their range of calibration capability.
Calibration can also be done at the user site using a portable flow rig (Figures 4 & 5). A portable rig does not provide
the same accuracy as a calibration lab, but it can calibrate
instruments to within +/-0.25 percent or better, depending
on the specifics of the flowmeter under calibration.
Portable flow calibration rigs offer convenience and speed.
Depending on plant topology, many measuring points can be
quickly calibrated with minimal interruption to a process. This
helps to minimize downtime or shutdown of the process, especially when fast turnaround and keeping production up and
running is most crucial.
Calibration labs typically handle larger size flowmeters with
larger flowrates. Portable flow rigs can handle flowmeters up
How to Choose Between Lab & On-Site

Calibration
The following summary of laboratory and on-site calibrations
is designed to help end-users identify the appropriate option
for different meter types:
Laboratory Calibration:
Best accuracy
Days to weeks turnaround
Larger calibration range1/24 to 12 and larger
Usually higher cost than on-site
On-site Calibration:
Good accuracy
Fastest turnaround (hours)
2 and smaller on rig3 to 4 in-line
Usually lower cost than laboratory
Flow Proving
Portable calibrations can also include flow proving. Flow proving is typically performed by the oil & gas industry on devices
used for hydrocarbon custody transfer. In proving, a transfer
standard is installed in-line with the flowmeter under test on
process fluid under process conditions. Specific requirements
for test methods and for documented results are required
January 2014 | 25
BEST PRACTICES | Flowmeter Calibration
in the oil & gas industry. Transfer standards can be master

meters, piston, small volume, ball, or bi-directional provers.
During proving, the flowmeter under test is compared to the
transfer standard and an external meter factor is determined,
based on the unit under test repeatability. Proving differs from
calibration in that its typically in-situ testing under process
conditions.
Verification
It is important to distinguish that unlike calibration, verification aims to provide evidence that a flowmeter fulfills certain
technical requirements of functionality as defined by the
manufacturer. It is usually a very detailed functional test to
confirm sensor and/or transmitter stability and produces a
qualitative outcome. Electronic verification consists of the
flowmeter and a verification system (Figure 6).
A verification system acquires a number of flowmeter parameters related to the flowmeter response. These values are
evaluated by a dedicated algorithm in the verification system
and the system parameter reference values. The result will
deliver the current status of flowmeter functionality. The final outcome is a qualitative assessment report based on a
pass-fail criterion such as process impacts, drift, or hardware
failures. The concept of verification must define the long-term
Figure 6. On-site flow verification performed with a test

and simulation deviceremoval of the instrument from the
pipe is not required.
stability of the test system, the stability of internal references,

and metrological traceable factory references for user confidence. In many cases, verification can be performed on less
critical meters or as a means to extend the calibration frequency.
A clamp-on ultrasonic flowmeter can be used to check a
flowmeters operation (Figure 6). While a clamp-on ultrasonic
flowmeter typically has only 25 percent accuracy, comparing the ultrasonic flow measurement to that of the installed
FLOWSTREAM
flowmeter can provide some level of confidence that the meter being tested is operating properly. Such a test is often
performed in concert with verification on very large flowmeters
in water and wastewater applications, or on other flowmeters
that are difficult to remove for full calibration testing.
Thanks to advances in flowmeter diagnostics and instrument management software, the increasing availability of
nearby calibration labs and portable calibration rigsand the
willingness of instrument vendors to help users with calibrationsetting up a flow calibration plan based on best practices is much easier than in the past.
Once set up, the flow calibration plan will improve operations and save money by making sure all flowmeters are calibrated only when necessary.
For instance, a food and beverage plant in Wisconsin was
having difficulty with compliance and had recently failed an
audit. With the time and resources they had to dedicate, they
realized they needed support. Working with the flowmeter
manufacturer, who had the knowhow and specialized in flow
calibration, they first began by performing an assessment of
all 300 flowmeters. After the assessment, the calibration plan
was set up. Based on criticality levels, the MPE and frequencies were determined. After performing the calibration on all
devices, all flowmeter data was stored in a calibration management software solution. Now the plant is able to easily
access flowmeter performance information, including calibration data and certificates. Solutions of this sort can help optimize the flowmeter calibration process, ensuring meters are
only calibrated when its actually necessary. FC
Ben Keizers is the product business manager for

Services at Endress+Hauser USA. Before moving to
the U.S. from his previous home in the Netherlands,
Mr. Keizers held various positions such as VP of sales
and marketing for a manufacturing company and
sales engineer at Honeywell Amsterdam. Mr. Keizers
holds a bachelors degree in Electrical Power and
Automation, as well as a bachelors degree in business engineering. He can be reached at ben.keizers@
us.endress.com or 317 535-1384.
Kyle Shipps is the calibration manager for
Endress+Hauser USA and has been working in
the Service Department for 13 years. He has held
previous positions as a Flow Product Specialist and
in Technical Support. Mr. Shipps has a bachelors
degree in Software Engineering and associates
degree in Electronic Technology. He can be reached
at 317 535-2185.
us.endress.com
Find related content @ flowcontrolnetwork.comSearch on:
Flow Calibration | Flow Proving | Flow Verification | Flowmeter Accuracy | Flowmeter Repeatability
26 | January 2014
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CASE STUDY | Ultrasonic Gas Measurement
TURNKEY
Natural Gas Measurement

Ultrasonic flowmeter optimizes gas
pipeline allocation system
OTAS, the state-owned oil & gas company in Turkey,

recently installed a natural gas pipeline allocation system at its natural gas compressor station at ayirli, a town in
the Erzincan Province of Eastern Turkey. The system included
a 42-inch ultrasonic flowmeter (Figure 1), one of the largest in the world, as well as supporting instrumentation from
Emerson Daniel Measurement and Control.
The compressor station pressurizes natural gas to 75 bar on the Erzincan pipeline at a flowrate that varies between 510,000 to 2,040,000
Sm3/hour (432 to 1,729 MMSCF/day)
throughout the year.
Unlike many allocation systems,
which typically consist of instrumentation and analyzers from various manufacturers, the Erzincan system was
delivered as a complete package that
was designed, configured, and commissioned by Daniel Measurement and
Control (daniel.com). The system was
designed with various redundant features to meet client requirements.
Six other pipeline instrumentation
companies bid on the project, but Emersons Daniel Measurement and Control
was the only company that could supply
all of the required equipment, instrumentation, and local engineering support along
with a redundant system. This simplified
the engineering and operational requirements for BOTAS (botas.gov.tr), because it
only had to deal with a single engineering
company. It also reduced the overall cost.
Another reason for awarding the
contract to Daniel was its technical
knowledge and domain expertise. For
example, Daniel worked with BOTAS to
perform calculations that allowed a re28 | January 2014
duction in line size from 46 inches to

42 inches, a change that resulted in
substantial savings without affecting the
systems design pressure.
Gas Ultrasonic Flowmeters

Ultrasonic flowmeters are widely used
in the natural gas industry for custody
transfer and other critical applications
because they cause no pressure drop,
which is a critical parameter, especially
on compressor station applications.
Also, they are immune to problems
caused by contaminants, have no moving parts, and offer enhanced diagnostic capabilities. Other benefits of
ultrasonic flowmeters include:
By Mehmet Duzen
Accuracy of +/-0.1 percent

Large turndown of 100-to-1
Bi-directional flow measurement
capability
Wet gas tolerance
Fault tolerance; meters remain
relatively accurate even after a
transducer failure.
Ultrasonic flowmeters are based on
the transit-time principle, measuring the
time of ultrasound pulses between a pair
of transducers determines fluid velocity. Each pair of transducers acts alternately as transmitter and receiver. Sound
pulses travel diagonally across the pipe,
downstream with the flow, and upstream
against the flow. The difference in transit
times of the downstream-directed pulses and the upstream-directed pulses is
proportional to the average flow velocity
along the acoustic paths, and is converted into an output signal and display of
volumetric flowrate.
However, a single velocity measurement path does not accurately represent flow. Therefore, multiple paths are
Figure 1. Daniel Measurement and Controls 42-inch SeniorSonic ultrasonic

flowmeter installed in the BOTAS pipeline.
measured inside the flow tube when

high accuracy is required. The number
of measurement paths and their geometrical arrangement is a main differentiator among ultrasonic flowmeters.
The Daniel 42-inch SeniorSonic ultrasonic flowmeter used in this system
(Figure 2) measures transit times on
four parallel chords.
A major attribute of ultrasonic flowmeters that brings substantial benefits
to operators is meter diagnostics, which
fall into two categories:
spare. The compressors feed pressurized

natural gas into a 42-inch pipeline, which
then flows through the allocation system.
The ultrasonic flowmeter measures
gas flow in the main pipeline, and a
Daniel gas chromatograph (GC) analyzes the gas (Figure 3). Gas energy
flowrate (kJ/hr) is determined by multiplying the volumetric flowrate (m3/hr)
as measured by the ultrasonic meter by
the calorific value (ISO 6976) (kJ/m3) as
measured by the GC.
The GC reports the energy and pro-
vides the detailed gas composition data

that are used for the volumetric flow
measurement. In addition to providing
measured calorific values, it ensures
quality flow measurements by providing compositional data necessary to
calculate the speed of sound. Speedof-sound comparisons assure the field
technician that the entire system is
within specifications and that the system meets requirements.
The instrumentation for the Erzincan
pipeline compressor station includes:
Four-path 42-inch Emerson Daniel SeniorSonic ultrasonic flowmeter
Emerson Rosemount pressure
and temperature transmitters
Two Emerson Daniel flow computers
Emerson Daniel 2350A gas chromatograph controller
Emerson Daniel Model 570 Danalyzer gas chromatograph (GC) complete with calibration gas and helium
bottles, as well as regulators
Analyzing the Gas
Figure 2. BOTAS natural gas compressor station at ayirli, a town in the Erzincan Province of Eastern Turkey.
The composition of natural gas includes

a variety of components (Table 1),
some of which are contaminants that
can reduce pipeline integrity over time.
At Erzincan, contaminant monitoring is
combined with energy measurement for
Functional diagnostics: monitors meter health and any signs of

hardware or firmware degradation.
Process diagnostics: monitors
stability of conditions in the metering
stream to ensure they are suitable
for applications where high accuracy
and reliable performance is critical.
A diagnostics package integrated with
the Daniel gas ultrasonic meter provides
BOTAS operators with an intuitive view of
meter functionality and status, and allows them access to real-time process
conditions. This ensures that system accuracy remains within specification and
alerts operators to address maintenance
alarms before they lead to failure.
Making Allocation
Measurements
The compressor station includes four
turbine compressors, which operate with
three units running and one unit as a
Figure 3. The allocation station on the Erzincan pipeline is fed with pressurized
gas from four compressors. A 42-inch ultrasonic flowmeter, flow computers, and
a gas chromatograph make the necessary measurements.
January 2014 | 29
Table 1: Natural Gas

Composition
Components
Mole Percentages
Methane
81.74501
Ethane
7.56130
Propane
5.50491
Isobutane
1.42323
n-Butane
1.49864
Isopentane
0.40214
n-Pentane
0.28643
n-Hexane
0.36973
Carbon Dioxide
0.96299
Nitrogen
0.24562
a complete allocation system analysis.

The GC (shown in the right corner of
Figure 3) takes its samples directly from
the pipeline, analyzes the gas for CH4 to
C6+, N2 and CO2, and calculates heating value, relative density, compressibility, and Wobbe index.
The GC is designed to operate unattended in hazardous areas. If adjustments
or troubleshooting are needed, its GC controllers Windows-based software allows
complete control and operation of the gas
chromatograph through a local operator
interface panel, or via remote connections.
The GC controller can link to multiple
PC workstations via RS-485, RS-422,
and Ethernet. Supported protocols include Modbus over RS-422 and RS485, as well as Modbus TCP over Ethernet. This allows remote diagnostics,
polling of alarms, and access to chromatogram reports on workstations from
anywhere in the GC controller network.
FC-B (Figure 3)receive inputs from

the ultrasonic flowmeter and from four
turbine flowmeters at the compressor
stations. The input from the ultrasonic
flowmeter is via an RS-485 link using
the Modbus protocol. The inputs from
the turbine flowmeters are via high frequency pulse signals.
The flow computers can provide
pressure, temperature, flow, and other
information via dual RS-485 Modbus
communications links to the pipelines
distributed control system (DCS) and to
plant operators.
An analog expander is used to double the analog signals that come from
each pressure and temperature transmitter associated with the four turbine
meters measuring fuel gas to each of
the four compressors. The inputs to the
expander are from the transmitters, and
the doubled outputs go to each of the
two flow computers.
Regarding Redundancy
In an allocation measurement system, downtime must be avoided to
reduce metering and operational costs.
Depending on how long such a system
is out of service, operating cost could
be significant. Redundancy was built
into the system from the beginning to
prevent such a problem and to achieve
a high degree of metering performance,
accuracy, and reliability.
Each flow computer receives measurements from all pressure, temperature, and flow instrumentation, plus the
GC. Temperature and pressure signals
from the transmitters installed downstream of the turbine flowmeters are
doubled in the analog expander and

then to each flow computer.
The turbine flowmeters send two
high-frequency signals, one to each flow
computer, and the 42-inch ultrasonic
flowmeter sends data over two RS-485
communication links to each of the flow
computers. Likewise, the GC sends data
over two RS-485 communication links.
Therefore, all five gas streams are
sending dual signals to the flow computers. If any of the systems fail, the
others step in to continue the allocation system calculations.
The ultrasonic flowmeter and gas
chromatograph use dual RS-485 digital
data with Modbus Protocol links to communicate with the flow computers, and
the flow computers and GC controller
each use RS-485 to communicate with
the DCS (Figure 4).
Process Parameters are sent from
the flow computers to the DCS. The
GC controller also sends the complete
measured gas composition data directly
to the DCS (Figure 4).
Modbus is used for several reasons.
First, it has a longer wiring distance
than fieldbus or Ethernet, allowing the
gas ultrasonic meter, the GC, and the
flow computer to connect to the control
system more easily. Second, it has better RFI/EMI noise immunity, especially
important in an environment with large
motor-driven compressors.
Finally, Modbus makes it easy to
connect multiple devices, including
Windows-based systems.
Startup & Commissioning

Before shipping to the site, the sys-
Organizing Inputs
The GC controller receives information
regarding gas composition from the GC
Analyzer via analog signals.
The ultrasonic meters onboard
electronics platform/transmitter collects
the pressure and temperature 4-20mA
outputs. It sends this data, plus volume
flow measurement information, to the
flow computers via an RS-485 link using the Modbus protocol.
Two flow computersFC-A and
30 | January 2014
Figure 4. The GC controller and two flow computers communicate with the DCS
using Modbus over a RS-485 digital data link.
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Figure 5. The availability of an accurate allocation metering system was a

key requirement in the development
of the new gas compression station
that will serve the natural gas pipeline running across northern Turkey.
FLOWSTREAM
tem was tested at Daniels facility

in Houston to ensure product performance and integrity. Standard Factory
Acceptance Test (FAT) procedures are
applied to each system component
before it is delivered to customers.
The FAT test certifies the product was
manufactured, tested, and inspected
in accordance with the material specifications and customer requirements to
ensure the product meets all specifications and is in compliance with industry
manufacturing codes and standards.
The start-up and commissioning
services were performed by Daniel. The
complete system, including the 42-inch
gas ultrasonic meter and the gas chromatograph were configured with the
two S600+ flow computers via RS-485
Modbus communications, and the commissioning was successfully completed.
Compressor Station performance
data shows that the meter is operating
within the stated accuracy limits of +\1.0 percent. Gas ultrasonic technology
will help provide an accurate measurement of natural gas delivery and the
overall transportation capacity of the
pipeline, which supplies energy to a
bulk of Turkeys residents (Fig 5). FC
Mehmet Duzen is a Regional

Business Development Manager with
Daniel Measurement and Control
at Emerson Process Management.
Mehmet oversees locations in the
Commonwealth of Independent
States (CIS) and Turkey. He has
worked at Emerson for 15 years in a
variety of roles in the area of hydrocarbon flow measurement, including
both the upstream and downstream
segment of the oil and gas industry
and other process industries.
www.daniel.com
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GUEST COLUMN | Training & Certification
Technical Knowhow
Marti Wendel
Making the case for a fresh perspective on fluid

power certification
he fluid power industry is

currently in need of professionals to invent new products, design efficient systems,
maintain existing equipment, test
components, sell products, teach,
apply, research, troubleshoot, etc.
So where are all the qualified job
applicants? Maybe supply and
demand isnt broken, but it might
have a glitch or two.
For many people working in the
Getty Images/
ThinkStock
field of hydraulics and pneumatics, finding job candidates with
experience has been a struggle of late, if not an outright lost
cause. And if the supply of qualified applicants isnt already
lean enough, the prospects for the future are even less promising. A recent survey taken by the Fluid Power Journal reports
that 47 percent of the people currently working in fluid power
today are 46 years old or older, with less than 2 percent of the
incoming workforce choosing this field. Of those surveyed, 16
percent have been in the industry over 31 years.1 With jobs
in fluid power waiting to be filled, the question becomes how
can the supply of qualified job seekers be increased?
Looking for Qualified Applicants
substantial amount of fluid power

content. Unfortunately, the typical
education requirement on a job
application for most engineeringrelated positions on monster.com
specifies a bachelors degree.
Other industries that are populated
with a mix of degreed engineers to
self-taught professionals require
certification to ensure anyone
practicing in that discipline has
the proper knowledge. In fact, an
electrician or plumber is not legally
allowed to perform any work on a
commercial building without being state certified. In fluid power, a self-taught mechanic or technician may need to make adjustments, reroute plumbing or, heck, even totally repower any
hydraulic or pneumatic system they have access to. Hydraulic
and pneumatic systems have the potential, if used improperly
or misapplied, to seriously damage property, injure personnel,
and even cause the loss of life. But applied correctly, hydraulic
and pneumatic systems also are fast, safe, flexible, and reliable, can provide overload protection, and are unmatched in
power density (size-to-power ratio).
To increase the supply of qualified fluid power professionals, employers need to encourage their employees and potential employees to be Fluid Power Certified. The International Fluid Power Society (www.ifps.org) offers 13 distinct
The logical place to look for young, well-trained job applicants

has historically been colleges and universities. Unfortunately,
due to already heavy curriculums, the
fluid power content taught to a mechanical engineering student during his or
To increase the supply of qualified fluid
her bachelors degree program is typipower professionals, employers need to
cally one class in Fluid Dynamics. It is
assumed the graduate will learn how
encourage their employees and potential
to apply hydraulics or pneumatics, if
employees to be Fluid Power Certified.
needed, from their future employer. This
increases the time before a new hire
can actually be productive and creates
additional concerns when the onus of fluid power education is certifications for anyone who has completed technical trainplaced on the employer. The new hire does not bring with them ing or is actively working in the fluid power industry. Through
the latest cutting-edge technologies that he or she might when certification, a potential employer can be certain that the new
freshly graduating from any other technical field. The graduate employee will be well-versed in the best and safest practices
simply learns how this particular employer has always done of fluid power whether or not they hold a four-year degree.
things, which may not be the safest or best practice method.
This is no criticism of the employer because, most likely, they Being Certified
too had on-the-job fluid power training.
The International Fluid Power Society (IFPS) is a nonprofit
Many associate programs and technical schools include a organization that provides an objective evaluation of the
34 | January 2014
individuals skills, and is recognized throughout all industries

that utilize fluid power. The skills required for the different
certifications range from advanced system design and controls expertise to fabrication of hose and tube assemblies.
The procedure used by IFPS to develop the certifications and
tests has been approved by Committee ASC B93, accredited
by the American National Standards Institute (ANSI, www.
ansi.org). All certifications are reviewed every five years,
sooner if deemed necessary by the IFPS board.
Like all proficiency certifications, the fluid power certification is owned by the person who earned it and travels with
them from employer to employer. Training employees and
then potentially having them leave doesnt sit well with many
employers, but to raise the bar on the personnel working in
this industry, proof of competency through certification should
be a requirement.
Training
The material in the IFPS certification study manuals is based
on industry standards and best practices and is an overview
of the material that will be represented on the test. For
those who already have a career in fluid power, continuing
education opportunities are also available through IFPS,
which can reveal new energy- and cost-saving techniques.
A study conducted by Oak Ridge National Laboratory (www.
ornl.gov) for the National Fluid Power Association (www.nfpa.
org) in December of 2012 states that fluid power system
efficiencies range from less than 9 percent to as high as 60
percent (depending on the application), with an average efficiency of 22 percent.3 With all of the new energy-efficient
technologies available to fluid power system designers, it
seems inconceivable that we are still operating at merely
22 percent efficiency. The need to teach best practices and
implement energy-saving concepts like load sense, pressure
compensation, variable-speed drives, closed-loop feedback,
etc. is essential to the growth of the fluid power industry.
Marti Wendel, a Certified Fluid Power Engineer, is

the sales manager for Curtiss-Wright Flow Control, Sprague
Products in Brecksville, Ohio, a manufacturer of specialty highpressure test pumps and boosters. She is currently the vice
president of education for the International Fluid Power Society
and is the Vice President elect of the IFPS Board of Directors
for 2014. Marti is past president of the Fluid Power Educational
Foundation, past president of her local Habitat for Humanity
Affiliate, and currently a Tae Kwon Do instructor for the Christian
Karate Academy. She graduated from Kent State University with
her bachelors degree in Industrial Technology and has worked
sales and engineering in the field of fluid power for 25 years for
employers in both manufacturing and distribution.
www.IFPS.org, www.curtisswright.com
sprague.cwfc.com
References
1. 2013 Salary Survey Results, Fluid Power Journal, May/
June 2013.
2. Why Get Certified? International Fluid Power Society,
www.ifps.org.
3. Estimating the Impact (Energy Efficiency and Economics)
of the U.S. Fluid Power Industry, December 2012, Oak Ridge
National Laboratory.
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Yes, the task of training needs to be pushed back on to the
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January 2014 | 35
THE PUMP GUY | Pump Reliability
mailbag: Lessons Learned

Larry Bachus
What industrial reliability teams can learn

from their counterparts in safety
36 | January 2014
David De Lossy/Getty Images/ThinkStock
bration analysis school.

The reliability engineer must
train the shop mechanics and the
equipment operators so they will
know how to contribute to reliability.
An emailed reliability mission statement will be received with the same
enthusiasm as all the previous Programs of the Month memos.
Walk down the hallway in your
Larry,
building and talk with the safety
engineer. Ask him about the corpoI am the new reliability engineer for
rate Safety Program.
a chemical company in the south.
I have a good friend, Rickie, who
My mission is to improve pump
instituted the Corporate Safety Proreliability at our site. I could use
gram at a global paper company.
some refresher training on pump
This is what Rickie told me about
basics. However, I have some
starting a safety program: Everyone
other concerns.
Much like safety, everyone has a role to play
practices and contributes to safety,
The company instituted reliwhen it comes to industrial reliability programs.
not just the safety engineer or the
ability as a department some 13
years ago at this facility. I am the fourth I dont know your company, and I have safety team. Everyone wears hard hats,
named reliability engineer at this plant. I never visited your plant. I can say there safety glasses, ear protection, and safeam due to go to vibration analysis train- is a definite reliability movement in the ty boots in the process area, including
ing in the coming weeks. We have four industry, and many reliability depart- the apprentices, part-timers, contracFFT spectrum analyzers that havent ments are showing impressive gains in tors, and secretaries.
Everyone goes to safety training, not
uptime of rotating equipment.
been used for months.
At the same time, I have visited re- just the safety officers. Everyone learns
My predecessor, the ex-reliability engineer, rotated into maintenance sched- cently with some reliability engineers why safety is important. Everyone learns
uling. He wishes me luck and says the who admit their program is faltering. to recognize unsafe conditions and situdepartment is ripe for improvement. I Your message indicates all is not well at ations. As a result, accidents and losttime injuries are reduced to almost zero.
met with some process engineers who your facility.
No program can advance if upper Today, most industrial sites are safe.
said our MTBF statistics are inflated
I asked Rickie, How does the safety
management doesnt believe in the prowith stand-by pumps.
How can I bring significant change gram and its merits. So you must deter- engineer institute safety as a corporate
to the Reliability Department? Do you mine if management is working for, or policy?
Rickie said, It is an uphill journey.
against you.
have any ideas?
It happens that some reliability pro- The corporate bigwigs will throw a little
grams falter even when management goodwill money at the project to see
Steve K.
wants the program to succeed. The re- what happens. Its like watering a plant
Reliability & Equipment Engineer
liability engineers strategy is flawed. I that you know might die.
The safety engineer uses that goodverified this recently. You cant start a
reliability program by sending out a bulk will money and studies the reports of
email to all company employees with plant-wide incidents, accidents, and inSteve,
the new Corporate Reliability Mission juries. The engineer identifies the most
I cant speak for your company because Statement and then disappear to a vi- unsafe place in the plant. He doesnt
new and interesting pattern is
developing in my work assignments in the last six months. My
last few pump consulting projects
have been with reliability engineers
in different plants. And this letter
to the Pump Guy illustrates the
changing pattern.
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THE PUMP GUY | Pump Reliability
Faltering Reliability Programs

tackle the whole plant at once.
You invest your efforts where you can show the highest Many companies employ or name a reliability engineer.
Sometimes the company names a reliability team. The engigains in a short time.
Maybe the central maintenance shop is the most unsafe neer (or team leader) is charged with improving reliability.
It is an uphill journey (Yes, these are Rickies words). The
place, or maybe the loading bay has too many accidents with
the forklift trucks, or maybe the package line workers get their corporate bigwigs throw a little goodwill money at the project
to see what happens.
hands and fingers mauled in the bottling machine.
The company purchases some vibration analyzers with
If the offender is the forklift truck accidents in the loading
bay, this can be corrected with driver training, mirrors, cam- training for the reliability team, and a few accelerometers for
eras, reverse warning signals, and rotating yellow beacons on trending.
Now the reliability engineer and his team tracks and trends
all fork-trucks so everyone can see and hear the forklifts as
they approach. The accidents and injuries disappear. Show thousands of fans, pumps, gear boxes, compressors, and
electric motors. They get bogged down in trending, tracking,
the accountants what you did with their money.
If the offender is cuts from glass, the remedy is leather or computing, and padding MTBF statistics. They fail to make
Kevlar gloves for all workers who handle glass, and proximity the vibrations disappear. This has to be frustrating.
So eventually the reliability team dissipates, the members
sensors to sound warnings, and even stop the production line
if a hand gets too close. The cuts and amputated fingers dis- rotate into other engineering and technical disciplines, and
the vibration analyzers gather dust under a table in the vibraappear. Document the reduction in cuts and stitches.
Maybe the remedy is painted yellow lines on the floor in tion office.
In the next board (bored) meeting, a VP says, I hear the
the shop to establish walking lanes for passers-by. The headreliability program is going gang busters at our competitors
bumps and trip accidents disappear.
The bean counters dont get excited when the accidents plant in Poughkeepsie. Lets hire a new reliability engineer.
As we say in Nashville, Same song, next verse! The exdisappear, but they get really excited when the lawsuits, the
insurance rates, and workers compensation claims disap- ercise begins again.
pear. Now the accountants understand the economy in havSteve, you said your reliability program began 13 years
LarryBachus-datescartoon:Layout
1 11/6/12
ing
all workers wearing hard hats, safety
glasses,3:56
and PM
ear Page
ago.1 Some reliability and vibration programs are approachprotectors.
ing 20 years in existence. Most are doing well. But a few
programs are stuck on first base. So, at what point do the
faltering programs go off-track and lose focus?
I think the faltering reliability programs go off track when
the reliability engineer attempts to tackle all of the rotating
equipment in a refinery, paper mill, or power plant.
The safety engineer attacks a specific unsafe areaor
specific unsafe conditionwith the limited funds to show
maximum improvements with minimal effort and time.
The safety engineer trains everyone in safety. The reliability
Larry Bachus ("The Pump Guy") is the
engineer trains himself and maybe a few key people. FC
co-author of Everything You Need to
Know About Pumps, one of the best
Regards,
selling technical books on pump systems in
The Pump Guy
the world. This book is written exclusively for
people who must maintain pumps. Whereas
Larry Bachus, founder of pump services firm Bachus
other pump books are written from a design
Company
Inc., is a regular contributor to Flow Control
point of view, this book is written with
magazine.
He is a pump consultant, lecturer, and inventor
maintenance in mind. While most technical
based in Nashville, Tenn. Mr. Bachus is a retired member
books sit on a reference shelf gathering dust,
this book gathers dirt smudges. Its pages get
of ASME and lectures in both English and Spanish. He can
creased and folded when mashed by the lid
be reached at larry@bachusinc.com.
of a photocopy machine. It gets sneezed on
and splashed with snot on cold mornings. It gets soaked with leaking oil, grease,
www.bachusinc.com
and coffee. Basically, it gets used ... because it's tremendously useful. The
straightforward guidance it provides will help you ensure the efficiency and
FLOWSTREAM
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Do You
Know & Understand
Your Pumps?
To order your copy of Everything You Need to Know About Pumps,

call (615) 361-7295 or order online at
www.bachusinc.com/books.html
38 | January 2014

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Seminar | Reliability | Safety
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uring Novembers Rockwell Automation Fair in Houston, an

over-riding theme was the role of cyber/information security
in enabling the Internet of Things for industrial manufacturing.
For those of you who are not in the know on all things hightech, the Internet of Things (or IoT for short) is the latest and
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In its most basic sense, IoT from an

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on analysis of key data points. Or, as
Keith Nosbusch, chairman and chief
executive officer for Rockwell Automation, put it during his opening address
at Rockwells Automation Perspectives
session at Automation Fair, A world
where billions of smart things and machines are connected to the Internet.
Citing statistics compiled by Cisco Systems, Nosbusch said the global IoT market
40 | January 2014
represents $14 trillion in value, 27 percent

of which is in manufacturing. With so much
potential revenue at stake, Nosbusch said
Rockwell believes IoT will accelerate the
adoption of the connected enterprise,
driving demand in manufacturing for such
IT-centric concepts as cloud computing,
mobility, and big data analytics.
Amid all of the optimism and excitement around IoT, the focus on the crucial
role of security was at the forefront of just
about every briefing I participated in during my two days at the Automation Fair.
much to do with its bet on EtherNet/IP

as the protocol of choice for enabling
industrial communications going forward. Rockwell has partnered with Cisco
Systems (www.cisco.com) to build out its
Connected Enterprise approach based
on EtherNet/IP, a protocol Rockwell developed in the 1990s, which is now managed by the Open DeviceNet Vendors
Association (www.odva.org).
At the 2012 Automation Fair in Philadelphia, EtherNet/IP was the key focal
point in much the same way that security was at the forefront of discussion
at the 2013 event. And the transition
from Ethernet to security makes sense,
as the success of Ethernet as a mechanism for connected industrial manufacturing scenarios depends on a robust
cybersecurity approach.
While Ethernet offers several compelling advantages, notably its ability to
easily network industrial machines with
traditional IT-based systems, connecting
industrial manufacturing to the Internet
is something that is greeted with hesitance among some end-user groups.
As weve worked with Cisco over the
years, weve worked very hard at creating a connected enterprise vision, which
is our view of the technology moving
manufacturing forward, said John Nesi,
vice president of Global Market Development for Rockwell, during his presentation at Automation Perspectives. But
a lot of that comes with concerns on the
part of our customers.
The two key worries Nesi cited were
cost and security. Regarding security specifically, Nesi said Rockwell and
Cisco are committed to proactively addressing end-user concerns with technology and best practices for securing
systems in connected environments.
EtherNet/IP & Security
Tackling the Cybersecurity

Challenge
Rockwells intense focus on security has
Robert Soderberry, senior vice president

and general manager of Ciscos Enterprise Networking Group,

said there are some basic building blocks for establishing a
secure foundation for industrial IoT, including:
1 Access Control: A lot of people when they think
about security, they think about this box right herea firewall. Firewalls are very important for security architecture, but
if your security architecture is a firewall, youre essentially unprotected. You have to be much more aware.
2 Awareness: The first thing you have to be aware of
is the contentwhat is this traffic that is moving around my
network? You need to be aware of that content at a deep
level, using things like deep packet inspection engines to understand what that content traffic is. It may look like good
traffic, but be bad traffic, and so on.
The second thing you need to be aware of is the context.
Whats the thing thats coming onto my network? Whats its
identity? Whats the device? What kind of data does it produce?
And you want to be sure of that identity. Is this device actually
in the location it says its in? Is it actually my device, or is it
somebody elses device? How do I securely connect into that?
Then I can marry context and content to make some interesting decisions. Ill let a machine with this type of signature
come into the manufacturing network, while a monitoring system with a different signature has to stay on the guest network.
3 Understand the Threat Landscape: Who are the
bad guys? What are the bad guys trying to do? What actions
are the bad guys likely to take? What actions are they taking now, and what is the next thing I need to do to protect
myself? All that information comes from being threat aware
understanding and being able to detect things like advance
persistent threats, malware, and all of the subtle layers of
threats that come into the environment today.
One of the complicated aspects of cybersecuring industrial

manufacturing environments, particularly in the United States
and Europe, is that most of the work will be on existing systems rather than in greenfield scenarios.
The gross majority of implementation will have to occur
over time, said Mike Asante, advisor and director for the National Board of Information Security Examiners (NBISE, www.
nbise.org), during his presentation at Automation Perspectives. Well have to take legacy technologies; technologies
that existed when security really wasnt required, because understanding that these systems would one day be connected
with business systems or to the Internet was not something
that the designers originally thought of.
In contemplating the key to a successful cybersecurity strategy, Asante said, If youre going to tackle securityyoure going to make enhancementsyou need to do it with a strong
partnership and trust with your automation supplier. They under-
stand the technology that theyve given you, and theyre the key
to understanding what can be done to secure that technology.
Cyber Threatscape & IoT Opportunities

So, as industry moves toward an IoT approach, cybersecurity
is a critical piece of the puzzle. But just how persistent and
dangerous is the threat? According to Asante, not only is
the cyber threat real, it is growing more targeted and structured. In fact, he said some estimates show up to $2 billion
is being invested annually in cyber attack tools designed to
enable advanced and targeted cyber attacks. Further, and
perhaps more concerning, he said up to 94 percent of the
victims of these advanced attacks arent the ones who detect
them. Rather, he said the notification comes from an outside
organization that, in most cases, discovers the attack when
information that belongs to the victim is found on an external
server in another part of the world.
And while the cyber threatscape is growing more advanced
and complicated, Asante says the move to create systems
and best practices to meet the cybersecurity challenge is underway and gaining necessary momentum.
What were doing is establishing underlying expectations
on what were demanding from the technology, and I think
thats really critical, said Asante. What Cisco and Rockwell
have brought to the table, if you will, are two big important
concepts. One is that security quality matters; and that means
that in the technology that they deploy, theyre going to have
securityits not a feature that you buy, its going to be inherent in the technology all the way from the network platform
level to the applications and down to the actual devices,
he said. The other element is that theyre going to invest in
developing security features. These features will allow the
customer to make the decision to add more robust security to
their systems as necessary.
So, I think youre going to see a diversity in approaches to
providing security, but some common expectations, said Asante.
To further the dialogue on industrial cybersecurity and IoT on
an ongoing basis, Rockwell announced the launch of its Industrial IP Advantage online resource center. The site, which is located
at www.industrial-ip.org, offers a community-based approach to
discussing and learning about trends, developments, implementation advice, and opinions on the use of IP in industrial applications. It offers tutorials, videos, infographics, discussions, and
other similar materials on topics such as Energy Management,
Mobility, Security & Compliance, and Remote Assets & Services.
For PDF downloads of the presentations from Rockwells
Automation Perspectives event, visit www.flwctrl.com/Auto
mationPerspectives2013. FC
Matt Migliore is the director of content for Flow
Control magazine and FlowControlNetwork.com. He can be
reached at Matt@GrandViewMedia.com.
FLOWSTREAM Find related content @ flowcontrolnetwork.com ... Search on:

Cybersecurity | Ethernet | Internet of Things | Matt Migliore | Process Automation | Rockwell
January 2014 | 41
WHO, WHAT, WHEN, WHERE, WHY? | Industrial Automation
WHY You Need

to Know About IPv6
e now live in an age where just about every piece of
information we interact with is stored on computers and/
or connected to the Internet. While the world of industry may
have lagged behind the consumer marketplace in this respect,
industrial systems are growing more connected with each
passing day. As the points of connection continue to rise, the
standards and protocols for managing them grow more important. This is where Internet Protocol (IP) comes into play.
IPv6
The initial idea behind internet protocol (IP) was essentially to build a directory for Internet addresses. As more
and more systems have come online,
the number of IP addresses has surged
into the trillions, and issues such as cybersecurity have risen into prominence.
The first major release of IP was
IPv4, and IPv6 is its burgeoning successor. The most notable difference between IPv4 and IPv6 is that it provides a
larger address space to accommodate
the growing number of connected devices. But there are many other capabilities that go along with the latest ver-
FLOWSTREAM
iStockphoto/Thinkstock
sion of IP, such as automated discovery

of routers, neighborhood resolution,
duplicate address detection, neighbor
unreachability detection, and, notably,
more robust cybersecurity features.
Kevin Davenport, business development manager at Cisco, says one of the
key cybersecurity features of IpV6 is First
Hop Security (FHS), which is designed to
secure and optimize IPv6 link operations.
The FHS solution protects networks by
mitigating attacks, such as router impersonation, address theft, address
spoofing, and remote address resolution
cache exhaustion. It also covers IPv6 link
By Jake Mastroianni
operation vulnerabilities and scalability

issues in large Layer 2 domains.
A majority of industrial cell communications on the plant floor occurs at Layer
2 (at the switch), says Davenport. In
fact, the Layer 2 domain is playing an
increasingly important role, with the IT
(enterprise) and OT (operational technologyconverged networks, server virtualization), Layer 2 mobility, etc., all resulting in larger Layer 2 domains.
This change brings with it an increasing number of challenges, says Davenport, such as security and scalability. In
parallel, he says IPv6 has been gaining
momentum as the next generation IP,
while the IPv4 address space continues
to run out.
If I had to select a single reason why
IPv6 is important for industrial automation and control systems going forward,
I would say security, says Davenport.
Today, all operating systemsfrom
servers to laptops to handheld devicessupport IPv6 (as well as IPv4).
If you spend millions of dollars securing your IPv4 infrastructures, but dont
consider IPv6, you are vulnerable to a
broader potential set of security holes.
More generically, Davenport says
IPv6 is important because it is the new
Internet Protocol version that is expected to be the future protocol standard for
years to come. If you want to ensure
a competitive advantage by developing
an infrastructure thats future-proof, deploying a converged network architecture based on IPv6 is imperative, says
Davenport. FC
Jake Mastroianni is the managing editor of Flow Control magazine.

He can be reached at JMastroianni@
GrandViewMedia.com.
Control Systems | Cybersecurity | Process Automation

42 | January 2014
W E LC OME S
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January 2014 | 45
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46 | January 2014
THINK TANK | HVAC
GLOSSARY OF TERMS: HVAC

AIR HANDLING UNIT: A central unit consisting of a
blower, heating and cooling elements, filter racks or chamber, dampers, humidifier, and other central equipment in
direct contact with the airflow.
CHILLER: A device that removes heat from a liquid via a

vapor-compression or absorption refrigeration cycle.
CONTROLLER: A device that controls the operation of
part or all of a system. It may simply turn a device on and

off, or it may more subtly modulate the set point of components.
S
R
ECONOMIZER: A component in the basic refrigeration cycle

that absorbs or adds heat to the system.
ENTHALPY: For a given sample of air, a measure of the
total heat content (the sum of the heat energy of the dry air
and heat energy of the water vapor within it).
HEAT LOSS: Terms for the amount of cooling (heat gain)
or heating (heat loss) needed to maintain desired temperatures and humidities in controlled air.
AIR HANDLING UNIT
LOUVER
INTERMEDIATE FLUID: A liquid or gas used to transfer
CHILLER
MAKEUP AIR UNIT
CONTROLLER
PLENUM SPACE
heat between two heat exchangers. An intermediate fluid

is used when the hot and cold fluids are too bulky or difficult to handle to directly transfer the heat.
ECONOMIZER
PSYCHROMETRIC
ENTHALPY
RADIATION
HEAT LOSS
SUBCOOLING
INTERMEDIATE FLUID
SUPERHEAT
LOUVER: 1. Components made of multiple smaller
Solve This Word Search

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blades, sometimes adjustable, placed in ducts or duct

entries to control the volume of air flow. When used inside
of ducts, their function is similar to that of a damper, but
they can be manufactured to fit larger openings than a
single-piece damper. 2. Blades in a rectangular frame
placed in doors or walls to permit the movement of air.
MAKEUP AIR UNIT: An air handler that conditions 100

percent outside air.
PLENUM SPACE: An enclosed space inside a building or other structure, used for airflow. Often refers to the
space between a dropped ceiling and the structural ceiling,
or a raised floor and the hard floor.
PSYCHROMETRIC: The study of the behavior of airwater vapor mixtures. Water vapor plays an important role
in energy transfer and human comfort in HVAC design.
RADIATION: The transfer of heat directly from one surface to another (without heating the intermediate air acting as a transfer mechanism).
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colder than the minimum temperature required to keep it
from boiling, which would change it from a liquid to a gas
phase. Subcooling is the difference between its saturation
temperature and the actual liquid refrigerant temperature.
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its boiling point at a specific pressure.
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January 2014 | 47
THINK TANK | Flow Measurement
By David W. Spitzer
quiz corner:
Typical Liquid Flow Velocity In a Pipe
hat is the typical design velocity

of a liquid flowing in a pipe?
A. 1 meter per second

B. 3 meters per second
Commentary
C. 5 meters per second

D. Any of the above
I suggest that Answer D is pragmatic.
If you already selected Answers A, B, or C, you likely jumped

the gun because the question is incomplete if the service
and fluid properties have not been defined.
Piping for liquids with low viscosity (such as water) are
typically designed to operate at between 2 and 3 meters per
second (Answer B). However, lower velocities may result when
the piping is oversized to include provisions for future plant
expansion and future increased flow.
Special consideration is often given in applications where
solids can drop out and plug the piping unless a high liquid
velocity is maintained (Answer C). On the other hand, while
higher velocity may reduce the probability of solids settling
out, higher velocity also accelerates pipe wear.
In other applications, liquid viscosity may be so high that
even flow at low velocity (Answer A) may result in an extremely
high pressure drop in the piping.
Additional Complicating Factors

There are many factors that can dominate the fluid velocity
design in pipes. Can you think of any others? FC
David W. Spitzer is a regular contributor to Flow

Control magazine and a principal in Spitzer and Boyes,
LLC, offering engineering, seminars, consulting, and expert
witness services for manufacturing and automation companies. He can be reached at spitzerandboyes.com.
David can be reached at 845 623-1830 or www.spitzerand
boyes.com. Click on the Products tab to find his Consumer
Guides to various flow and level measurement technologies.
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David W. Spitzer | Flow Measurement |

Flow Velocity | Pipe | Quiz Corner
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48 | January 2014
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How Reliability Can Learn from Safety Strategic Flow Calibration Ultrasonic Gas Measurement

SOLUTIONS for FLUID MOVEMENT,

JANUARY 2014 Vol. XX, No. 1

Write in 1 or Request Info Instantly at www.FlowControlNetwork.com/freeinfo

Viega ball valves feature:

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january 2014 | Vol. XX, No. 1

Vr Reverse Velocity (m/s)

dv/dt Deceleration (m/s2)

Addressing the Big Bang

Flow Calibration Considerations

Turnkey Natural Gas

GUEST COLUMN: A Case for

By Ben Kelzers & Kyle Shipps

Flow Control (ISSN #1081-7107) is published 12 times a year

POSTMASTER: Send address changes to: Flow Control, PO BOX

A controlled circulation publication, Flow Control is distributed

Do you know whats

the road ahead

what reliability can learn from safety

rockwell automation fair recap

42 WHY you need to know about ipv6

On the Cover: Images courtesy of ThinkStock.

NEWS & NOTES

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The Road Ahead

s we kick off the 2014 calendar year, one of

not will fall.

Did You Know?

EXECUTIVE DIRECTOR OF BUSINESS

EDITORIAL ADVISORY BOARD

Larry Bachus: Bachus Company Inc.

According to Cisco, the number of devices and

Flow Control Magazine

2014 Badger Meter, Inc.

Industrial Oval Gear Flow Meters

THE OUTLOOK | News & Notes

Is Steam a Reliable Measurement

o calculate energy usage

The simple answer would be the

ogy employed, any particular vortex

read some value. To make the problem

Cleve Nyberg has 25 years of process control experience with a strong

7 Reasons to Use/Not Use Steam as a

Flow Control Magazine

best practices & standards

ISA100 Industrial Wireless Standard Enters Final

submitted, will carry the designation IEC

companies, hoping to ensure consideration of the views and requirements

Festo Offers Free Resources to Aid OEMs with Safety

esto (festo.com), a provider of

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