Flow eHandbook Finalv2

8/22/2019 Flow eHandbook Finalv2

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Flow eHadbook

Best Practces for FlowStart u



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Table of CotetsSpecfy the Rght Slurry Seal 6Consider new dual-seal and water-management options

Get the Most Out of Your Fas ad Pumps 11 Variable requency drives can help reduce energy costs and improve motor eciency

Groud EMFs wth Vrtual Referece 14New grounding method eases electromagnetic fowmeter installation and minimizes costs.

Determe Boler Sze Usg a Flowmeter 18An inline vortex meter reveals the proper steam usage, resulting in signicant savings

and improved energy eciency.

Product Features Vorte Flowmeter Measures Temperature 3

Varable Speed Drve Eases Commssog 4

Federal Equpmet Acqures McQuay Process Chllers 9

Vorte Flowmeter Measures TemperatureSPiRAx SARCO’S VLM10 inline vortex owmeter com-

bines an inline vortex meter, a built-in ow computer and an

integral temperature sensor.

Te owmeter handles mass, volumetric and energy ow

measurement on steam, liquid and gas applications o 1 inch

to a oot. Te VLM10 is capable o a steam or gas mass ow accuracy o ± 1.5% o range over a 20:1 ow range. Te ully

welded, gasket-ree design, helps ensure sae steam measure-

ments and allows the sensors and RD to be removed without

rst having to shut down the line.

Te built-in web server allows customers to monitor ow

and meter health through the internet. Digital communications

deliver inormation on demand using Modbus RU, BACnet

MS/P, and Modbus CP/IP technology with standard analog

and pulse outputs.

Te VLM10 is available in a range o connections and

pressure ranges.

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Ad ideSemes 2usa.siemens.com/Coriolis

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Varable Speed Drve Eases CommssogTHE P1000 variable speed drive rom Yaskawa delivers simple, reli-

able, cost-eective control or variable-torque loads through 500 hp.

Specic application eatures, energy savings and network connectiv-

ity make the P1000 a great choice or industrial ans and pumps. Te

P1000 includes application presets or easy commissioning. A real-

time clock (built into the keypad display) can be used or system con-

trol based on time o day, and also can provide time-stamped event

inormation. Primary and secondary PI process control loops helpregulate both drive-related and non-drive-related process variables.

Te P1000’s dynamic noise control minimizes drive-related au-

dible motor noise under light load conditions. It also has ast-acting

current and voltage limiters or tripless operation, communication interaces or all major industrial networks,

and preventative maintenance monitors that provide alarms or scheduling work beore problems occur.

An auxiliary control power unit keeps the drive communicating when main power is removed. In addition,

a USB copy unit can help easily duplicate drive conguration and a removable terminal board with parameter

storage provides automatic conguration backup.

Built-in DC reactors (30 HP and larger) provide input harmonics and protection rom input disturbances.

For low harmonics, a cost-eective integrated 12-pulse version (480V, 40 hp and larger) is available. A ange

version provides cabinet mounting efciency (heatsink external) with a high integrity dust-tight solution

(NEMA 12). Te P1000 is made with RoHS-compliant materials or environmental responsibility.

Click the image above to watch a video about the P1000.



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Specfy the Rght Slurry SealConsider new dual-seal and water-management options

By Heinz P. Bloch, consultant, and Tom Grove, AESSEAL Inc.

in THE 1990s, slurry-sealing trends moved

strongly rom braided packing toward single-type

heavy-duty mechanical seals. Still, mechanical

seals oten are among the irst components toail; whenever ine abrasive slurries can migrate

into the seal aces, the perormance o mechani-

cal seals becomes especially unpredictable. Yet,

virtually all modern process plants place great

importance on reliable mechanical seals. Facili-

ties experiencing repeat ailures may ind that

better slurry seals now available enable eective

remedial action. For mild slurries, single-type

heavy-duty mechanical seals with springs located

away rom the pumpage (as illustrated in Figure

1) oten suice. For more diicult slurry services,

best-in-class companies typically speciy dual

seals (Figure 2).

SPECiFiCATiOn STRATEGiES

oday, top reliability proessionals select these dual

seals by invoking and urther ampliying the Ameri-

can National Standards Institute (ANSI)/Hydraulic

Institute (HI) Rotodynamic (Centriugal) Slurry

Pump Standard ANSI/HI 12.1-12.6-2011 [1]. Section

12.3.8 o this standard describes general arrangement

details or mechanical shat seals. It states that dual

pressurized seals have the advantage o providing enhanced lubrication to the aces with a pressurized

barrier uid. Tis arrangement prevents process uid

leakage to the atmosphere and so improves saety. Te

standard urther notes that dual pressurized seals are

used when the limits o heavy-duty single mechani-

cal seals are exceeded, when air potentially can be

entrained in the slurry, or when large volumes o air

can be introduced into the pump. Experience shows

that both the seal environment and seal ace materials

must be careully selected or the service. Buer uid

pressurization requirements and associated controls

are important as well.

Figure 2 depicts a dual pressurized seal design. Te

inboard set o seal aces contains the process slurry

or impure pumpage; a secondary barrier uid (clean

water) is pressurized higher than the process stream. An outboard set o seal aces connes the clean barrier

uid. Te higher pressurization means the secondary

barrier orms the inboard-seal-ace uid lm. Seal ace

ailure risks normally originating with micron-size-

range particle contaminants are mitigated because

the seal-ace operating environment is clean water at a

stable pressure.

Delivery o the water barrier uid is important to

application success. raditional piping congurations

are API Plan 53-A and API Plan 54. Plan 53-A is

limited by a xed volume o barrier uid; a uid-

containing vessel or “seal pot” is externally pressurized

by air or nitrogen. During process upset conditions,

the pressurized volume o uid crosses the inboard

seal ace, and the seal pot must be recharged during

operation. Tis recharging process is not operator-

riendly — so there’s high likelihood the seal will run

dry. Plan 54 is a centralized water-barrier distribution

Figure 1. This type o heavy-duty unit oten handles lime slurry services.

SinGLE-TYPE MECHAniCAL SEAL

Seal ace set




system, usually through multiple pumps. Tis means

the circulating system always must be pressurized 15

to 30 psig above any seal chamber pressures to avoid

cross contamination o the barrier uid.

Leading processors have had success with

hybrid solutions whereby Plans 53 and 54 are

combined and water comes rom a sel-contained

water-management system (Figure 3). Te system is

designed to control pressure and cool the seal aces;

it uses a regulator and a backow preventer to set

the correct water-barrier pressure or the seal aces.

Te water is recirculated, reducing actual con-sumption to just a ew gallons per year. An inline

lter connected to the continuous source o water

lters the barrier uid to 1 micron absolute. A

three-way valve in the line returning rom the seal

to the reservoir enables the operator to inspect the

condition o the barrier uid in the seal without

compromising seal perormance. Should any parti-

cles cross the inboard seal ace, the three-way valve

is activated to ush the seal. An internal standpipe

on the supply line to the seal protects the sea l rom

contaminants. By connecting a valve and drain

line to the bottom o the tank, an operator can

purge contaminants rom the reservoir while the

connected water source automatically replenishes

the system with clean water. I process air bubbles

accumulate at the seal ace, the secondary liquid

provides sufcient cooling to ensure consistent

seal perormance. Te size o the seal pot and the

positioning o the inlet and outlet ports determine

the level o heat dissipation by the support system.

Independent control o the seal environment

broadens the success margin or the seal.

A recent U.S. Environmental Protection Agency rule tightened the caps on sulur and nitrogen oxide

emissions. As a consequence (although appeals are

pending), processors are giving ever-closer attention

to equipment reliability and efcient use o existing

pollution-control technologies. In late 2011, the U.S.

Department o Energy outlined “near-term compli-

ance pathways,” highlighting the need or increased

utilization and reliable perormance o wet and dry

ue-gas desulurization (FGD) units [2]. O course,

selecting reliable mechanical seals is o critical impor-

tance, not only in FGD, but also in the majority o

other slurry applications. New dual-seal and ush-

water management options allow users to upgrade

rom maintenance-intensive packing to highly reliable

mechanical seal alternatives. Moreover, in large pump

sizes, designs that allow seal insta llation rom the wet

end o the pump, which will minimize the cost o

overhaul, deserve to be considered.

Plant reliability proessionals should consider

bridging the distinct operating parameters o nu-

merous slurry-containing processes with existing

industry standards or slurry sealing. o incorpo-

rate the options outlined above requires important

amendments to current equipment standards.

he add-on wording should state:

• e mechanical seal must be a heavy-duty dual-

cartridge mechanical seal suitable or slurry duty

and designed to operate at all times at a higher

pressure than the process pressure.

• Seal internal cross-sections must have large

radial clearances; the inboard ace set must be

hydraulically balanced to the barrier uid.• Tungsten carbide (TC) and/or silicon carbide

(SiC) aces matched with solid C aces must

be used when the pH is greater than 5; solid

SiC must be used when the pH is 5 or less.

Pin drives must be designed to minimize ace

racturing.

• Wetted alloys must be super duplex for abra -

sion resistance.

• Mechanical seals must perform equally with or

without impeller back-vanes; the user requests

that back-vanes be incorporated in the equip-

ment impellers.

A DUAL MECHAniCAL SEAL

Figure 2: The space between the sleeve and the inside diam-eter o the two sets o seal aces is lled with a pressurizedbarrier fuid — usually clean water.




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• e seal chamber must be an open-frame plate

liner with vortex breakers or a closed-rame plate

liner designed to prevent excessive erosion.

• A mechanical seal support system must be

provided as a pre-engineered turnkey system;

it must include all instrumentation and ttings

necessary or site installation.

• e tank must have a minimum capacity of

25 liters (6.6 U.S. gallons) and be sel-lling.

Inboard seal ace integrity must be visually

conrmable at the support system with a ow

indicator.• e distance between the seal supply and

return port should be a minimum o 15 inches

to maximize residency time or barrier-uid

heat dissipation.

• e system at all times must deliver barrier

uid at pressure dierentials 15 psig (mini-

mum) above the process pressure in the pump

stufng box.

• e seal system must include inline ltration of

plant seal water to 1 micron. An internal stand-

pipe on the supply leg, a three-way valve on the

return leg, and a blowo valve at the bottom o

the tank must be included to allow clearing the

system o any contamination ater the initial

installation and during its service lie.

• As part of the initial supply package, documen-

tation must include a heat generation report or

each installation. Te report must reer to the

operating conditions or the intended shat di-

ameter, speed, process/barrier pressure, tempera-

ture and induced ow. Te data must provide

the input or a thermal equilibrium estimation

and result in a calculation o the heat generated

by the specic seal supplied in each case.

As regulatory legislation issues persist, a thought-

ul compliance strategy will drive sealing solutions

that truly optimize reliability o slurry pumps in

virtually a ll industries.

HEinZ P. BLOCH, P.E., is a Westminster, Colo.-based

process machinery consultant. TOM GROVE is executive

vice president o AESSEAL, Inc., Rockord, Tenn. E-mail them at

[email protected] and [email protected].

PRE-EnGinEERED WATER-MAnAGEMEnT SYSTEM

Figure 3: A sel-contained system can supply water or dualmechanical seals while minimizing makeup water.

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The Emerson logo is a trademark and a service mark of Emerson Electric Co. © 2011 Emerson Electric Co.

YOU CAN DO THAT

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Get the Most Out of Your Fas ad Pumps Variable requency drives can help reduce energy costs and improve motor eciency

By Christopher Jaszczolt

THE MAjORiTY o an and pump applications

spend little to no time requiring the motor to runat rated speed. On average these motors can meet

demand by running at 70% o shat speed. Te

additional system capabilities are usually reserved to

accommodate uture expansions and/or inrequent

increased load demands. Carious controllers can be

utilized to run a motor at reduced speed. One such

motor controller is a variable requency drive (VFD).

A VFD is a reliable electronic device that efciently

operates a three-phase electric motor. It can be used to

efciently operate a an or pump motor at any speed.

Operating a an or pump motor below base speed

to meet the requested demand can show signicant

energy savings over the same motor run across the line.

Te energy saving benets o utilizing VFDs in an

and pump applications have been well established and

documented. Te costs o a VFD and its installation

or various pump and an systems can usually be paid

back in energy savings within a ew years.

VFDs save energy in pump and an applications

by taking advantage o their variable torque load pro-

les. Te variable torque load proles present in these

types o applications can be expressed through the

afnity laws. Te afnity laws convey the relationshipbetween shat speed, volumetric ow rate, and power.

Afnity Laws:

I. Flow is proportional to shat speed:

Q Out

Q Rated

N Out

N Rated

= ( )II. Pressure or Head is proportional to the square

o shat speed:

H Out

H Rated

N Out

N Rated

= ( ) 2

III. Power is proportional to the cube o shat speed:

P Out

P Rated

N Out

N Rated

= ( ) 3

Where:

Q – Volumetric ow rate (CFM, GPM, etc),

N – Shat rotational speed (RPM),

H – Pressure o head developed by the an/pump

(eet, meters, etc.),

P – Shaft power (Watts, HP)

For example, running a motor at 70% o rated

speed should only require approximately 34% o rated

power to generate the 50% torque required to produce

the 70% ow demand. Tereore, using a VFD will

require 64% less energy to run a motor and meet the

required load demand than the same motor running

directly across the line (neglecting savings associated

with inlet vane and/or output damper control).

• 70% motor speed provides g 70% rated ow

g by using 50% o rated torque g at 34% o

motor rated power.

As this scenario demonstrates, the energy savings

is usually realized through the comparisons made

between a motor run across the line and motor run

by a VFD at reduced speed. Additional savings are

realized though reductions in peak demand chargesresulting rom the VFDs sot-starting capabilities. A

motor starting across the line will draw 6 to 7 times its

rated current, while a VFD will draw current rom its

power source linearly with respect to the output power

demand. Te transormer eeding the VFD will never

see the initial current surge required to start the motor.

Furthermore, a VFD can be urther congured or ad-

ditional energy saving by improving motor efciency.

Most VFDs are congured to output voltage to a

motor based on a constant torque volts-per-hertz (V/)

pattern. Constant torque V/ patterns are required

when the load torque is independent o speed. As




a result, a motor must be able to generate constant

torque throughout a motor’s speed range. Tis can be

generated by creating constant ux, which is obtained

by maintaining a constant voltage-to-speed relation-

ship. Tis can usually be described by the relationship

between base voltage and base speed.

A 460 volt, 60 Hz rated motor will require 7.67

volts-per-hertz to generate constant torque through-

out the motors speed range. Tereore, constanttorque V/ patterns generally have linear relationships

between the amount o voltage provided to the motor

and its running requency. Tere may be a slight in-

crease in voltage in the motor’s low end speed region

to help generate starting torque. A urther voltage

boost will be added to the output to oset the voltage

drop associated with winding impedance.

On the other hand, we have already expressed that

an and pump applications are variable torque loads.

Variable torque loads are applications where the load

torque required to drive a motor is dependent on

shat speed. As we have already expressed through the

afnity laws, torque is proportional to the square o

shat speed. Tereore, a constant torque V/ pattern

is no longer necessary because the motor no longer

needs to generate constant torque below rated speed.

In act, running a motor applied to a variable

torque load, with a VFD congured to output based

on a constant torque V/ pattern, will reduce the mo-

tor’s efciency. In some instances, running a motor

designed or a variable torque load prole, with a

VFD congured or a constant volts-per-hertz output,

can cause the motor to go into saturation and draw high current. Te resulting current draw may some-

times exceed the motor’s rated ull load amps, which

i not corrected can cause the motor to overheat.

As a result, VFD manuacturers have congured

VFDs to incorporate pre-established V/ patterns spe-

cically designed or variable torque loads. Tese V/

patterns have the output voltage strategically reduced

to generate the typical torque requirements o variable

torque loads throughout the motor’s speed range.

However, not every motor has the same design. As

a result, these preset V/ patterns could still be over-

saturating the motor, which reduces motor efciency.

Tis is where a VFDs automatic energy-savings unc-

tion can be utilized.

By design, VFDs operate motors by varying their

output voltage waveorm’s undamental requency in

order to vary motor speed. Te applied requency is

such that the motor operates within its normal ull

load slip rating, where rated slip is only applied at rat-

ed load. VFDs generate voltage waveorms with lower

slip in order to meet the lower torque demands o the application. As slip decreases urther and urther

away rom rated slip, the motor becomes less and less

efcient. Most AC induction motors are designed or

maximum efciency at rated slip. Tereore, a VFD

will only run a motor near its optimum efciency

while running at rated load.

A VFD’s automatic energy-savings eature is

designed to be utilized whenever rated torque is not

required. Since an and pump applications are al-

most never run at rated load, a VFD’s energy-savings

eature will operate whenever the pump or an is

called to run.

Energy-savings control will regulate a VFD’s

output voltage such that the motor always runs at

rated slip in order to continuously optimize mo-

tor efciently, regardless o the load condition. A

VFD’s energy-savings unction optimizes slip by rst

determining the amount o power being supplied to

the motor. Ten, the VFD calculates the amount o

power that should be supplied to the motor based on

the requency range, tuned motor parameters, and

power measurements. Once the VFD has calcu-

lated the right amount o slip to run the motor at itsmaximum theoretical efciency, the output voltage

is adjusted until the ca lculated amount o slip is

achieved. Tereore, energy savings control improves

motor efciency by regulating the amount o slip

through adjustments in the output voltage. Te V/

pattern is specically adjusted or each motor at every

given load condition. Energy savings control will al-

low the end user to avoid conguring V/ patterns or

using unreliable pre-determined V/ patterns that may

decrease motor efciency or perhaps place the motor

in an over-saturated condition.

Te VFD’s energy-savings control is simple to




setup and use. Te eature is generally initiated by en-

abling a parameter setting during the VFDs installa-

tion. Ten a simple one-time auto-tune with the load

uncoupled rom the motor must be perormed. Te

tune allows the VFD to ascertain key motor inorma-

tion for its energy savings calculations. With a VFDs

capability to auto-tune motor data, the type o motor

becomes irrelevant.

Figures 1 and 2 show the power required to run a

motor applied to the same variable torque load withand without energy-savings control. Te series in

blue (V/) designates a VFD running the load with

a deault constant torque V/ pattern. Te red series

(V/ + ES) has the VFD running the motor under the

same load condition, with the VFD’s energy-savings

unction enabled.

As we have previously stated, the V/ pattern using

energy saving will have its output voltage continu-

ously adjusted away rom the deault pattern to opti-

mize slip. As the gures show, energy-saving control

utilizes less power to run the same load by optimizing

motor efciency. Te energy saving unction will

provide a larger reduction in power consumption the

lighter the load becomes. As gure 2 shows, energy

savings has a marginal eect on motor efciency

at higher speeds. As the motors draws nearer and

nearer to rated speed, the motor will run nearer and

nearer to rated load. Tus, the motor will run closer

and closer to rated slip. Since the motor’s optimal

efciency point is at rated slip, the VFD’s energy

savings control will not have to make any signicant

motor-efciency improvements.

On the other hand, the torque requirement will besignicantly lower in the mid- to low-speed range. As

a result, the motor will not be running near its rated

slip. Figure 1 shows a VFD’s energy-savings control

unction can be used to substantially increase motor

efciency at lower speeds. For example, energy-savings

control is able to reduce the power requirement to run

this motor at 60% o shat speed by nearly 10%.

Furthermore, the VFD can still generate a constant

torque V/ pattern i the load demands reach or exceed

the motor ratings. Tereore, energy savings control al-

lows a VFD to seamlessly generate high starting torque

without any adjustment to the V/ pattern, while still

having the ability to back the voltage o automatically

to run the motor near its optimum efciency.

Additionally, energy-savings control allows orreal-time adjustments. By making rea l-time power

measurements, the VFD can accommodate or motor

parameter changes that may have been aected due to

motor temperature changes. Tereore, any unex-

pected load or motor characteristic changes will be

automatically compensated or by the VFD.

Energy-savings control is a eature that may

already be imbedded into your VFD. Te benets

described using a VFD’s energy-savings control isn’t

limited to an and pump applications. Any applica-

tion where there are long periods o light loading can

benet rom a VFD’s energy-savings control.

Figure 1

Figure 2




ELECTROMAGnETiC FLOWMETERS (EMFs)

are one o the leading choices or recording the

volume ow o electrically conductive liquids in

a wide range o industries, including chemical,

pharmaceutical, water/wastewater and ood. Like all

electrical equipment, EMFs must be grounded or

saety reasons. Grounding is typically done using

conductive non-lined pipe ange, grounding rings,

or occasionally, grounding electrodes.

However, in some applications these standard

grounding methods can pose problems. For example,

in lines with cathodic corrosion protection or in

galvanization plants, voltage is generated between the

electrodes and the earth. Or, when using aggressive

media in the application, the grounding rings oten

must be manuactured rom special materials that are

very expensive, which adds signicantly to costs when

dealing with large nominal widths.

With a new method called virtual reference, also

known as virtual grounding, EMFs can be insta lled

in any type o pipeline, without grounding rings orelectrodes. Te method acilitates the use o less-

expensive plastic nonconductive piping, which would

otherwise require grounding rings or disks that can

be quite expensive, reducing the cost savings inherent

in plastic piping. It’s also ideal or use in chlorine

alkali electrolysis plants, where very low voltages and

strong currents cause stray currents on liquids owing

through pipes, which can disturb measurements.

Finally, it can be used in circumstances where atty

substances like emulsions may coat suraces inside

pipes, reducing the conductive connection needed or

proper grounding.

EnSURES ELECTRiCAL iSOLATiOn

Te EMF’s basic measuring principle relies on

Faraday’s Law o Induction, which requires that

the inner wall o the measuring tube be electrically

isolated. Tat’s why most EMF measuring tubes or

chemical applications are lined with polytetrauoro-

ethylene (PFE), peruoroalkoxy (PFA) or polypro-

pylene (PP), or made entirely o ceramic.

EMFs must be grounded in accordance with

saety regulations to ensure protection against con-

tact and prevent electric shock. Tis guarantees that

in the event o an error there’s no hazardous voltage

to the conductive parts o the device. In addition,

grounding provides a xed reerence potential to the

EMF signal voltage.

Tis EMF signal voltage is typically about a mil-

livolt or less. Te converter can only process such small

signals without intererence and with maximum resolu-

Groud EMFs wth Vrtual RefereceNew grounding method eases electromagnetic fowmeter installation and minimizes costs.

By Ral Haut, Krohne, Inc.

Figure 1. Electromagnetic fowmeters typically requiregrounding using either conductive non-lined pipe fange,

grounding rings or grounding electrodes.




tion provided there’s not a great dierence between the

potential (the voltage) o the medium and the reerence

potential o the signal processing in the converter.

GROUnDinG METHODS

Tere are several grounding methods available.

Standard grounding methods include conductive

non-lined pipe ange, grounding rings or grounding

electrodes. In addition, there’s the virtual reerence

method, which is done without separate grounding

o the medium.

Conductive non-lined pipe fange : Tis is the sim-

plest grounding method, used in pipelines that are elec-

trically conductive on the inside (or example, blank

steel or stainless steel). Te liquid in the pipe has the

same potential as the grounded pipe. Te signal voltage

on the electrodes thus has a xed reerence potential.

Grounding ring or discs : For ceramic, plastic or

concrete pipelines and or lines isolated on the inside,

the product is brought to a known xed potential,

usually by the use o metal grounding rings (ground-

ing discs). Te ring is in conductive contact with the

product and usually jointly grounded with the sensor. When assembling the pipeline and the EMF

anges, two additional gaskets are usually necessary.

Groundings rings and gaskets must not disturb the

ow prole at the measuring point. Careul selec-

tion and assembly o grounding rings and gaskets

will prevent leaks.

Tis method is technically reliable and has been

proven or many decades. Disadvantages include

higher costs when special materials are needed or

aggressive media or in the case o large pipe sizes.

Tere are some instances in which the cost o the

grounding rings exceeds that o the EMF itsel.

In addition, when there are electrical potential

dierences, stray currents will occur between the

product and the earth via the grounding rings and

the grounding cable. Te grounding rings can be

destroyed as a result o electrochemical reactions

with the product. Since they can be expensive, this

solution has signicant cost implications.

Grounding with grounding electrodes : With this

method, the grounding electrode is situated at the

invert o the pipe and is in direct contact with the

housing that’s connected to unctional earth (FE) o

the EMF sensor. Oten, the cost o this additional

grounding electrode is less than grounding rings.

In the event o electrical potential dierences in the

plant, these grounding electrodes can be destroyed

by electrolytic action, resulting in leakage or de-

struction o the whole EMF.

Abrasive solids in horizontal pipelines can also

quickly destroy these grounding electrodes. In some

cases, deposits on the grounding electrode can pre-

vent the proper unction o the product grounding,

thus inhibiting correct measuring results.

In the case o large EMFs with grounding elec-trodes, signicant deviations also occur when — as

is oten the case — the EMF was ca librated in an

electrically conductive pipeline and then used in an

isolated pipeline.

Virtual reerence : Using this method, the EMF

sensor can be installed in any type o pipeline without

grounding rings or electrodes. Te converter’s input

amplier records the potentials o the measuring elec-

trodes and a patented method is used to create a volt-

age that corresponds to the ungrounded liquid’s po-

tential. Tis voltage is used as the reerence potential

or signal processing. Tus, there are no interering

Figure 2. This diagram compares standard grounding methods with virtual reerence.




potential dierences between the reerence potential

and the voltage on the measurement electrodes.

Tis method has several advantages: For one,

method has no need to come in contact with the

product. Te elimination o grounding rings and

simpler EMF installation results in lower costs. Tis

advantage shouldn’t be underestimated, as aulty

grounding is the most common cause o error when

commissioning an EMF. Tere’s no risk o electro-lytic destruction when there are potential dierences

in the system, such as when using grounding elec-

trodes. In addition, no stray currents ow over the

product or grounding lines. Ungrounded use is also

possible where voltage and current are applied to the

pipeline, such as with electrolytic and galvanic treat-

ment. Te virtual reerence method can be used on

pipes with a diameter (nominal width) rom DN10

(3/ 8-inch) and conductivity o ≥ 200 micro Siemens

per centimeter (µS/cm).

ViRTUAL REFEREnCE in PRACTiCE

Andritz AG, headquartered in Austria, uses EMFs

or pickling steel, an acid treatment used to clean

o the surace and remove coatings resulting rom

the production process, giving the raw metal parts a

better surace nish. Te ow o mixed acids, con-

sisting o hydrouoric acid, nitric acid and water, is

measured. At 90°C and a pressure o 3 bars (194°F,

43 psi), the acid ows at a speed o approximately

1.5 meters/second (5 t/second).Te extremely cor-

rosive uid would ordinarily have required corro-

sion-resistant rings made o tantalum. Tese ringsare exceptionally expensive, costing about 1.5 times

more than the price o the EMF instrument itsel,

so the company was interested in using another, less

expensive, grounding method.

Andritz opted to use Optiux 4300 EMFs, in

sizes o DN10 to 300 (3/ 8 inch to 12 inch), manu-

actured by Duisburg, Germany-based measuring

instrument manuacturer Krohne. Te Optiux 4300

uses Krohne’s patented virtual reerence method.

According to automation engineer Helmut

Platzer, there are many advantages to using virtual

reference. “Without this virtual reference electrode,

grounding rings would have to be used. Te rings

must be made o dierent materials or dierent

media, which would make it easy to conuse them

during installation.” He expressed concern that this

could result in problems, because the chemical re-

sistance is uncertain. He adds, “Also, these ground-

ing rings can be very expensive, so not using them

results in a signicant reduction o cost.”

Switching rom a built-in reerence electrode

to a virtual electrode was technically easy. Another

actor in avor o virtual reerence is that Andritz is

using small-sized pipes, where an external reerence

electrode could not be mounted. “Virtual reerenceperormed well in every instrument in which we’ve

installed it. Tere have not even been problems with

difcult applications, such as the mixture o two

acids with dierent temperatures right beore the

EMF,” says Platzer. Te use o Optiux EMFs with

virtual reerence made device installation aster and

reduces costs in many ways.

Virtual reerence perorms reliably, even in the

harshest conditions. I pipe diameter and product

conductivity conditions are satisfed, the EMFs

can be installed in all systems in which classical

grounding is a challenge.

Figure 3. An Andritz acility opted to use electromagnetic fowmeters with virtualreerence grounding in an extremely corrosive process that normally wouldrequire expensive corrosion-resistant rings.




You’re searching for an efficient flow measurement solution?

No problem with KROHNE.

As one of the world’s market leaders for flow measurement instrumentation, we’ve been

serving our customers in the process industries for more than 85 years with innovations that

set the standard for our markets.

KROHNE has the widest range of technologies and unique expertise. Our know-how applies

to general applications, and also to requirements that demand tailor-made solutions.

There’s practically no fluid that our devices can’t measure reliably and securely: Aggressive

or abrasive; high or low temperature, pressure or viscosity; media mixtures with high solids

content or high purity fluids as well as saturated or superheated steam.

KROHNE – process measurement engineering is our world.

Always a good solution

Variable Area

Coriolis

Magnetic

Vortex

Ultrasonic

[email protected]

Tel: 1-800-FLOWING

us.krohne.com

























WHEn iT comes to making big decisions involving

capital purchases, it’s best to do so with accurate inor-

mation. Having the right inormation requires having

the right data, and sometimes having the right data re-

quires making accurate measurements. Such is the case with one company that sought to make changes in the

way it generates steam or its manuacturing acilities.

Garlock Sealing echnologies, LLC (GS), a

company that manuactures uid sealing components

such as compression packing, gaskets, expansion

joints and dynamic seals, uses steam to operate some

o its manuacturing equipment. Teir operation

encompasses several buildings. Tereore, the central

boiler that supplies each o them must produce super-

heated steam to accommodate the steam temperature

requirements o each machine.

It takes a lot o extra energy to superheat steam

just to compensate the temperature drop that occurs

as steam travels to where the equipment is located.

For this reason, GS plans to decentralize steam

generation at this location by installing a boiler or

each product line.

Although a project o this magnitude is a signi-

cant commitment requiring a considerable invest-

ment, there are measurable benets. Decentralizing

steam generation will allow GS to accommodate the

equipment at each site without having to superheat

the steam. It will also allow them to save energy andlower maintenance costs.

MEASURinG COMES FiRST

For a company to measure benets or savings, it must

rst understand the benchmark to which it must

compare. Initially, GS estimated the steam ow

required or one o their product lines. Based on as-

sumptions — instead o actual measurements — they

thought they needed a 25,000-lb boiler.

Fortunately, GS has a close working relation-

ship with its regional Spirax Sarco sales engineer.

Because they rely heavily on this engineer, they trust

his judgment and occasionally seek his advice.

Te Spirax Sarco sales engineer convinced GS to

install an inline vortex meter into the main steam line

or the building to determine the steam usage or the

selected product line. Te sales engineer worked withGS’s personnel to ensure the meter was properly

sized and using less steam in this building than it had

originally. Based on the sales engineer’s calculations

and inormation rom the company, it was recom-

mended to reduce the line size rom 6 inches to 2

inches to accommodate a 2-inch inline vortex meter.

RESULTS SPEAK FOR THEMSELVES

With the line size reduced to accommodate the ap-

propriate meter size or the application, the inline

vortex was able to accurately capture the steam ow

over the entire ow range.

With the inline vortex, GST was able to trend the

actual steam going through the pipes, which resulted

in the need or a 15,000-lb boiler instead o a 25,000-

lb boiler or the specic product line. Vortex meters

require no maintenance and thereore, GS didn’t

have to worry about wear or recalibration.

Now that the GS is able to quantiy steam usage

accurately, they can potentially use the inline vortex

to understand the characteristics o their system

to nd leaks and other potential problems. I GS

decides to move orward with other opportunitiesthat can help them save energy, the inline vortex will

give them the inormation needed to enable capturing

those savings in the orm o less steam usage.

Tis meter application was successul because

the Spirax Sarco sales engineer took time to calculate

steam usage and advised the customer regarding the

proper meter size to capture the entire ow range.

Te customer is impressed with the perormance

o the inline vortex owmeter and the inormation it

provides. Because o their satisaction with this meter,

they intend to purchase and install another vortex

meter or a dierent product line.

Determe Boler Sze Usg a FlowmeterAn inline vortex meter reveals the proper steam usage, resulting in signicant savings

and improved energy eciency.




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