Processing - August 2014

August 2014

Featured Article

www.ProcessingMagazine.com

Control Regulator for Natural Gas Applications

The PGR-1 Pressure Gas Regulator valve from Cashco, Inc. is a high-

accuracy, pressure-loaded, pilot-operated, pressure-reducing regu-

lator. Available in 1, 1, 2, 3 and 4-inch body sizes, with more

to follow, the PGR-1 comes in four basic materials with multiple

trim-material combinations. This regulator conigures for operat-ing temperatures ranging from -70 to +250 F and outlet pressure

set points between 2-inch water column and 200 psig, depending

upon body/cover and dome/diaphragm material combinations.

The PGR-1's capacity is the highest in the industry, Cashco says.

As a result, users can often use a smaller body size than if they

were using a competitive regulator in the same application. For

more information on valves & actuators, turn to page 22.

Cashco, Inc.www.cashco.comWrite In 500

Valves & Actuators

Universal Ultrasonic Gas Flowmeter

The OPTISONIC 7300

universal ultrasonic

gas lowmeter is an economic solution

for gas-low, process and auxiliary mea-

surements in oil and

gas reineries and chemical and petro-

chemical plants. It is,

in fact, the measurement of choice for non-

custody-transfer natural gas applications.

It delivers beneits as well when applied to compressed-air, mixed-gas, steam or lue-gas measurement. For more information on

lowmeters, turn to page 30.KROHNE, Inc.us.krohne.comWrite In 503

Featured Column

Bulk Bag Material Conditioner with Pivoting Conditioning Arms

Discharging bulk bags full of material thats solidi-

ied, hardened or agglomerated can bottleneck operations. Moreover, without the right equip-

ment, conditioning and emptying bulk bags is

dangerous. A patented system from Material

Transfer & Storage, Inc. has hydraulically actuated,

heavy-wall tubular-steel pivoting conditioning

arms. Each conditioning arm features v-shaped

tubular steel breaker proiles that safely return solidiied materials to a free-lowing state. For more on powder & bulk solids, turn to page 40.Material Transfer & Storage, Inc.www.materialtransfer.comWrite In 502

Pneumatic Conveying System

Smoot Co.s patented ECOPhase pneumatic-conveying system has a special entrainment

device called a Magveyor to allow continuous operation while achiev-

ing high solids loadings. Manufacturing facilities can take advantage

two ways: New installations can reduce the horsepower needed to

convey dry-bulk solids at a given rate and distance. Existing installa-

tions can run more eficiently on current horsepower, increasing max throughput for a given line. The ECOPhase pneumatic-conveying sys-

tem helps users to better achieve their energy- and cost-reducing goals,

in some cases by more than 50 percent. For more information on

pneumatic & mechanical conveyors, turn to page 36.Smoot Companywww.magnumsystems.comWrite In 501

Whats in my bin?

No matter by what means the inventory is monitored in a bin, tank or silo,

the invariable irst questions always is, How accurate is it? Sometimes its not an easy question to answer. To better understand bin-level accuracy

and why some believe multi-point measurement beats single-point, peruse

this article on user expectations for level-monitoring systems. Read more

on page 6.

Packaging Expo, Pharma Expo and the cross-pollination of ideas

In the late 1970s, the U.S. military developed

a retort pouch for carrying ield rations. Today, retort pouches package consumer

goods from juices to soups to baby food.

Its a good example of how applications of

impactful technologies unfold across indus-

tries based on the cross-pollination of ideas. Increase your chances

of having the right market insights by attending this years PACK

EXPO. Read Julie Ackermans column on page 35.

Subscribe:Subscribe to the print edition or the digital edition.

Go Global:Subscribe to Global Processing magazine in digital format. Stay informed. Sign up for Global Processing weekly newsletters.

E-News:Sign up for Processing newsletters.

e-news

Like us:Like Processing magazine on Facebook.

Follow us:Follow Processing magazine on Twitter.

Complete Solutions for Process Measurement and Control at omega.com

DPi1701 SeriesStarts at

$300

Visit omega.com/dpi1701

omega.com COPYRIGHT 2014 OMEGA ENGINEERING, INC ALL RIGHTS RESERVED

1-888-826-6342

SPRTX-SS Series$95

PRS-M12 SeriesStarts at

$121

PX409S-USBSanitary Series

Starts at$585

DTG-RTD100 SeriesStarts at

$395

Visit omega.com/sprtx-ss

Visit omega.com/prs-3-100-m12

Visit omega.com/px409s-usb

Visit omega.com/dtg-rtd100

Prices listed are those in effect at the time of publication and are subject to change without notice. Please contact OMEGAs sales department for current prices.

18 DIN Graphic Display Panel Meter and Data Logger for Temperature and Process Measurement

s Monochrome, High Resolution Graphic Display

s Universal Input Accepts Thermocouples, RTD, and Process (Voltage and Current)

s Displays Process Input in Horizontal Bar Graph, Line Graph Charting, or Standard Digital Format

s Records 85,000 Data Points with Time Stamping

Sanitary RTD ProbesStandard and Heavy-Duty with M12 Connector

Provides Quick and Easy Installation in CIP and Sanitary Processes

Connector/TransmitterFor Sanitary Pt100 Probes with M12 Connector Splash-Proof Body and Integral Cable

Built-InTransmitterHousing!

USB Output Sanitary Fitting Pressure Transducer Connects Directly to Your PC or Laptop

Digital RTD Thermometer316 SS Enclosure for Wash-Down, Sanitary and Marine Applications

Write In 100

See the full range of fast-payback equipment at flexicon.com: Flexible Screw Conveyors, Tubular Cable Conveyors, Pneumatic Conveying Systems, Bulk Bag Unloaders, Bulk Bag

Conditioners, Bulk Bag Fillers, Bag Dump Stations, Drum/Box/Container Dumpers, Weigh Batching and Blending Systems, and Automated Plant-Wide Bulk Handling Systems

CC-0878

GUARANTEED SOLUTIONS

USA

[email protected] 888 FLEXICON

2014 Flexicon Corporation. Flexicon Corporation has registrations and pending applications for the trademark FLEXICON throughout the world.

*Patent(s) granted and/or pending.

**See full Lifetime Performance Guarantee for details.

CHILE

UK

AUSTRALIA

SINGAPORE

SOUTH AFRICA

+56 2 2415 1286+44 (0)1227 374710 +61 (0)7 3879 4180+65 6778 9225+27 (0)41 453 1871

FLEXICONFlexible Screw Conveyors

FLEXI-DISCTubular Cable Conveyors

PNEUMATI-CONPneumatic Conveying Systems

Convey free-flowing and difficult-to-handlematerials that pack, cake, seize or smear

Prevent separation of blends Convey short to medium distances Conveyor routing at any angle, through

small holes in walls or ceilings Only one moving part contacts material Fast disassembly, thorough cleaning Stationary or mobile units, including

tilt-down models Economical to purchase, install, operate

and maintain Single or multiple discharge points Minimal power usage 3-A and USDA compliant or

industrial models

Slide fragile materials gently throughsmooth stainless steel tubing using low-friction polymer discs attached togalvanized, stainless or Nylon-encapsulated stainless cable

Prevent separation of blends Short to long distances Durable discs in 4 and 6 in.

(100 and 150 mm) diameters Available CIP accessories Single or multiple inlets/outlets can be

removed/relocated and the cable-disccircuit lengthened/shortened/re-routed

Minimal power usage Evacuates material, minimizing waste

and cleaning time

Single-point up-and-in installations to cross-plant systems with multiple pick-up anddischarge points and automated controls

Positive pressure and vacuum dilutephase systems complete with blowers,rotary airlock valves, pick-up adapters,filter receivers, cyclones, fill/pass valves,wands and weigh batching controls

Short to long distances Wide capacity rangefeed small

packaging lines to silos and railcars Single or multiple inlet and

discharge points Total evacuation of supply vessel and the

conveyor line for accurate weighments,minimal waste and easy cleaning

Convey free- and non-free-flowing bulk materials at low cost

Convey fragile bulk foods and non-foods gently

Convey free-flowing materialsshort to long distances

Stand-alone units to weigh batching configurations to automated plant-wide systemsbacked by Flexicons Lifetime Performance Guarantee**

To Your Specific Bulk Material Conveying Problem

Condition material solidified in bulk bagsBLOCK-BUSTER Hydraulic Bulk

Bag Conditioner loosens bulk

material that has solidified during

storage and shipment, enabling

bulk bag unloaders to discharge it

through bag spouts. Two hydraulic

rams with contoured conditioning

plates press opposing sides of bulk

bags. The number and pressure

of ram actuations, the height of

the turntable, and the degree of

rotation are user-programmable.

Intended for bulk bags containing

solidified chemical and food products that cannot be loosened

efficiently by pneumatically actuated flow promotion devices

integral to bulk bag unloaders. System controller and hydraulic

pump can be mounted on safety cage exterior or remotely.

Requires only an electrical power connection for operation.

Empty bulk material from drums dust-freeTIP-TITE Drum Dumper seals

drum against a discharge cone,

tips the drum, mates the cone

against a gasketted connection,

and discharges bulk material

dust-free through a slide gate

valve. The drum platform is

raised by a single hydraulic

cylinder, creating a dust-tight

seal between the drum and

discharge cone. A second

hydraulic cylinder tips the plat-

form-hood assembly and drum,

stopping at dump angles of 45, 60 or 90 degrees with

a motion-dampening feature. The cone mates with a gasketted

inlet port fitted to receiving vessels or process equipment.

Accommodates drums from 30 to 55 gal (114 to

208 liter).

Untie, discharge, retie andremove bulk bags dust-freeBULK-OUT Discharger features a

SPOUT-LOCK clamp ring* that

creates a high-integrity, clean seal

between bag spout and hopper,

preventing contamination and dust

during hook-up and discharge.

TELE-TUBE telescoping tube

raises the clamp ring to make

connection, then lowers, applying

continual tension to keep spout

taut as bag empties/elongates,

preventing dead spots and flow

restrictions. POWER-CINCHER

flow control valve* cinches the spout concentrically for easy,

leak-proof retying of partially empty bags. BAG-VAC dust

collector creates negative pressure within dust-tight system to

collapse empty bags prior to retying and disconnection,

eliminating dust from manual flattening of empty bags.

Weigh batch and blend bulksolids automaticallyFLEXICON Self-Contained, Auto-

mated, Gain-In-Weight Batching

System can be integrated with new

or existing processes and conveyor

systems, or supplied with Flexicon

pneumatic or flexible screw con-

veyors to transport materials from

any upstream source to any down-

stream destination. Controller starts/

stops each conveyor or rotary

airlock valve to weigh multiple

ingredients in sequence, first at

high feed rate, then at dribble

feed rate prior to stopping

material flow once the accurate

batch weight has been reached. Automatically compensates for

material-in-flight. Allows concurrent blending of the discharged

batch and weighing of a subsequent batch for fast cycle times.

Elevate, tip and dischargeboxes/containers dust-freeTIP-TITE High-Lift Box/Con-

tainer Dumper discharges dust-

free into vessels 6 to 10 ft (183

to 305 cm) high. Accom-

modates containers 36 to 48 in.

(915 to 1220 mm) on a side,

and 39 to 44 in. (990 to 1117

mm) in height. Hydraulically

raised container platform cre-

ates dust-tight seal between top

edge of container and underside

of discharge hood. Second

hydraulic cylinder raises plat-

form-hood assembly vertically,

before tipping it to a motion-dampened stop at 60 degrees

beyond horizontal, causing discharge cone to mate with

receiving vessels inlet port. Slide gate valve prevents

material flow until discharge cone is seated.

Connect bulk bags safely,rapidly at floor levelSWING-DOWN Bulk Bag Filler*

lowers and pivots the fill head,

stopping it in a vertically oriented

position. Places the bag inlet

spout inflatable connection,

inflator button, and four bag loop

latches within one arms length of

an operator standing on the plant

floor, allowing safe, rapid bag

connections. Eliminates danger of

stepping onto and over roller

conveyors to access rear bag

hooks and spout connection

collars, standing on the conveyor with head and arms inserted

beneath operational fill head components, and straining to pull bag

spouts upward over inflatable collars while reaching for bag inflator

buttons. Available to industrial, food, dairy and pharmaceutical

standards with numerous performance enhancements.

Write In 170 Write In 171 Write In 172

Write In 173

Write In 174

Write In 175

Write In 101

In This Issue26 Whats in my bin?

Understand bin level accuracy and why multi-point trumps single-pointmeasurement

12 The latest current concerns How supervisory and leakage currents affect todays low-power solenoid valves

20 The new must have its dueOff-the-shelf valve automation packages are a better way of doing things

24Vent&laregasmeteringintheoil &gasindustry Thermal mass low technology seen as suited for unpredictable process conditions

32Usetrackandtracetomeetdrugsupply chainsecurityregsSecure the pharmaceutical industrys future with marking technologies that support regulatory compliance

35PackagingEXPO,PharmaEXPOandidea cross-pollination Solutions for food and pharmaceutical industries bloom in an industrial-creativity

hothouse

4 ProductivityPerspectives10 Tanks & Vessels

22 Valves & Actuators

30 Flowmeters

36 Conveyors

38 Mixing,Blending&SizeReduction40 Powder&BulkSolids42 Process Control & Instrumentation

44 IndustryBriefs46 InfoCenter47 Classiieds48 Index

August 2014 volume 27, number 8

August 2014www.ProcessingMagazine.com

32

Explosion Vent

Integrated Safety Monitoring Filter

Backdraft Damper

AIR POLLUTION CONTROL

Farr Gold Series

Industrial Dust CollectorChoose from a full range of

explosion protection optionsIncluding:

TM

www.camfilapc.com888-804-4716

IT LOOKS LIKE A SAFE BECAUSE ITS

Scan QR Code, Place Phone Here

Turn your phone into a window to actually see inside

the Farr Gold Series.

CHEMICAL ISOLATION EXPLOSION VENTFAST-ACTING VALVE

VERTICAL PLENUMDETECT AND SUPPRESS

AND MORE

BACKDRAFT DAMPERBLAST PLATE

Write In 102

August 2014www.ProcessingMagazine.com

Industrial America used to throw oil and water together with abandon. That led to the devel-opment of industrial oil skimmers, which have ways to take advantage of the two luid sub-stances well-publicized aversion to each other.

Less of this throwing together occurs today, due to well-recognized wastewater issues, amongst other reasons. Yet this greater aware-ness hasnt led to general idleness amongst oil skimmers. The same sensitivities that culminate in less mixing have also brought to the table new, both broadly commercial and unforeseen niche applications.

Such is life at the Chagrin Falls, Ohio-based Oil Skimmer Division of Abanaki Corp., says Simon Bennett, VP of sales & marketing and long-time company veteran. Its a simple prin-ciple that cant be beat, Bennett says. A belt, held between two pulleys removes primary con-tamination prior to iltration.Exploiting surface tensions

Oil skimmers work by making use of the dif-ferences in speciic gravity and surface tension between oil and water. Its used in steel mills. In manufacturing plants its used to skim loating oils from wastewater sumps. Its used in paper-making, food processing and wastewater indus-tries, Bennett says.

Because ilters are such a large capital expense, Bennett says, he knows of food pro-cessors that have vacuum trucks come in to skim the top off of collection pits. In some

cases, avoiding just two vacuum-truck service calls would justify the expense of a skimmer.

Just about any cooking process makes use of oil, Bennett says, they will do a washdown at night with water running through the drainage system to a central tank. After treatment, that water is either recycled or sent into the efluent.Always the new

Thus the food & beverage industry has been a driver of growth for Abanaki industrial oil skimmers. Cooking facility oil can be recycled rather than incinerated. You get money for what you used to throw out.

Other developments Bennett admits he didnt see coming. For example, in recent years the company has sold dozens of oil skimmers to auto-dismantling yards in the United Kingdom, a mom-and-pop type business there, and one that came under the scrutiny of regulators.

Today there are solar-powered oil skimmers for the upstream oil & gas industry. Gasoline can be skimmed, and innovative applications emerge from developments related to belt materials. Thats part of why you ind industrial oil skimmers in power plants, steel mills, mines, reineries, factories and machine shops and all the other exotic locales mentioned above.

4

Reader Advisory Board

Robert J. Bockserman, President, ConatechPeter S. Cartwright, President, Cartwright Consulting Co.

Barry Charnay, President & CEO, Whisper Ingredients Inc.

Ken Delafrange, President, Jadee Inc.Don Graham, President, Graham Sanitary Design Consulting, Ltd.

Stanley Herzog, President, Princeton Process Technology Consultants

B. George Kniazewyz, President, RenovareEric Langer, President, BioPlan AssociatesEd Marshall, President, Maintenance Management Technologies

JohnStansield, Plant Manager, Accelerated Curing Inc.

Dr. Jesse Yoder, President, Flow ResearchRobert M. Donnelly, Vice President of Marketing, Flo-Tite Valves & Controls

Kevin Parker, Editorial Director

[email protected]

Group Publisher, Mike WassonPh: 973-539-7715, Email: [email protected]

Editorial Director, Kevin Parker Email: [email protected]

Managing Editor, Nick Phillips Email: [email protected]

Associate/Web Editor, Christy UnderwoodEmail: [email protected]

Art Director, Ryan CarlsonEmail: [email protected]

Marketing Manager, Mary Beth RomanoEmail: [email protected]

Advertising Sales Assistant, Cookie RayfordEmail: [email protected] Administrative Team:

General Manager, Barry Lovette

Vice President of Operations, Brent Kizzire

Vice President of Finance, Brad Youngblood

Group Director of Circulation & Fulillment, Delicia PooleCirculation Manager, Anna Hicks

Circulation Analyst, Stacy Barnes

PROCESSING (Pub.#ISSN 0896-8659)

PROCESSING Magazine is published monthly by Grand View Media Group. Editorial and Executive Offices: 200 Croft Street, Ste 1, Birmingham, AL 35242. Periodicals postage paid at Birmingham, AL & additional mailing offices. POSTMASTER: Send address changes to PROCESSING Magazine, PO BOX 2174, Skokie, IL 60076-7874. SUBSCRIPTIONS: Non-qualified domestic subscriptions: one year, $57; two year, $99; single issue, $10. Canadian and foreign surface subscriptions: one year, $93; two year, $162. Air mail subscrip-tion: one year, $203; two year, $355. Grand View Media Group, 2014. PROCESSING Magazine assumes no responsibility for validity of claims in items reports.

For Subscription Questions/Inquiries:U.S. 866-721-4807 Outside U.S. 847-763-1867E-mail [email protected] / Renew / Change of Address:www.processingmagazine.com/subscribe

Productivity Perspectives

Write In 103

Dedicated to the proposition oil and water wont mix

Write In 104

August 2014 www.ProcessingMagazine.com

For any means to the monitoring of bin, tank or silo inventories, a irst question invariably asked is, How accurate is it?

Unfortunately, its a loaded question. It cant be answered easily. But heres a discussion about why its a tough question, and what can be expected from a level-monitoring system.

First to consider is the type of device used. Bobs, guided-wave radar, open-air radar and ultrasonic level sensors are the common cur-rency. What's common is a measurement taken from a single point in the vessel. installed prop-erly any can be expected to perform to stated measurement accuracy.

But, what does the stated accuracy of mea-surement mean? For a single-point device, accuracy is often expressed based on the distance measured from the tank tops sensor to the material surface. This distance is often referred to as headroom, because it delin-eates how much space is left in the bin. This can

usually be accurately expressed within 0.25 percent of the total distance measured.

However, thats not a direct indicator of accu-racy in the bin materials calculated volume or mass; its the accuracy of that single measure-ment.

Whats really wanted is volume, the amount of three-dimensional space the material takes up. If whats known is the distance from the sen-sor to the material surface, estimated volume is from that and the internal vessel dimensions. Known, accurate vessel dimensions help, but material low, buildup or bridging can affect volume calculations. Sensor placement and ill-ing and discharge point locations also impact volume calculation.Mass calculations

Accuracy is further impacted when using a single-point measurement device to estimate mass or weight. When converting volume to

mass, the bulk density of the material stated in pounds per cubic foot or lb./ft.3 can sig-niicantly impact accuracy. Although available resources reference a particular materials bulk density, that of the material actually in the bin can be quite different than whats posted on the Internet.

Particle shape, size and moisture content all impact bulk density. Material compaction also can cause very different bulk densities at bin top and bottom, for the same material. A cubic foot of material at the top of the bin could weigh less than that same material at the bot-tom, where the bulk density is greater due to compaction by material weight.

When using bulk density to calculate bin mass for a particular material, its important to estab-lish an average bulk density based upon the actual material, not an amount stated in a refer-ence table. One way to do this is taking mea-surements before and after a known-weight

A History Steeped in Innovation.

Cashco, Inc.

P.O. Box 6, Ellsworth, KS 67439-0006 | Ph. (785) 472-4461, Fax: (785) 472-3539 | www.cashco.com

Pilot Operated

Tank Blanketing Systems

CELEBRATING 100 YEARS

When quality counts . . . choose Cashco. For 100 years,

the industry has turned to Cashco for precision control

solutions. The Model 1088 is a pilot operated tank-

blanketing valve that allows tanks to be controlled with

tighter tolerances. This unit has multiple flow plugs,

sensing configurations, and body configurations in order

to meet the specific needs of the end user.

Broad product lines provide solutions for virtually any project.

Superior quality product surpassed only by the service and support.

Strategically located Service Centers with factory-trained specialists.

Dont wait any longer to partner with the industrys

leader in process control. Call us today.

Model 1088

Write In 105 Write In 106

By Jenny Nielson Christensen

WHAT'S IN MY BIN?Understand bin level accuracy and why multi-point

trumps single-point measurement

Material low, buildup and bridging affect volume calculations. Sensor placement and illing and discharge points add complexity as well.

Write In 107


8

>

LEARN MORE

Visit us at the Powder ShowSeptember 16-18, 2014Somerset, NJ

www.smootco.com

Toll Free 800.748.7000

ECOPHASEPNEUMATIC CONVEYING.

CUT ENERGY CONSUMPTION

AND $AVESMOOT CAN MOVE IT

USING LE$$HORSEPOWER.

PATENTED

Write In 108

Tanks & Vesselsload is put in the bin, and then adjusting the bulk density in lb./ft.3 to relect this weight.

For single-point level mea-suring, further error is expected from the conver-sion of distance to volume and then mass.

As stated, measured-dis-tance accuracy

is around 0.25 per-cent. However, when level

is used to estimate volume, accuracy depends upon correct, complete vessel dimensions, as well as information about sensor placement and location, and number of illing and discharge points. A vessel that is center-ill, center-dis-charge, with material low free and symmetric, gives best results with single-point measuring.

Inherent inaccuracies when converting a vol-ume calculation to a mass calculation are due to bulk-density variations, regardless of whether single-point or multi-point measuring is used. Volume calculation accuracy impacts mass calcu-lation accuracy.

With so many variables, single-point level-measurement device makers struggle to pinpoint how accurate the calculated mass value will be. However, with accurate vessel geometry, strate-gic sensor placement of the sensor, and a good average bulk density, mass accuracy of around 8 percent to 15 percent can be expected.Multi-point accuracy

Unlike traditional devices that measure dis-tance from a single point, a 3DLevelscanner from BinMaster measures from multiple points within the silo to determine bin material volume. Measurement points are not averaged to calcu-late bin volume. Instead, each point is weighted for relevancy. A complex algorithm calculates the bins true material volume. By this means varia-tions across the topography of the material sur-face are taken into account through measuring and mapping of high and low points.

The scanner conigures an accurate three-dimensional proile of the storage materials top surface. This is a beneit when there are material-surface variations due to multiple ill and dis-charge points, or with materials such as powders that do not ill or discharge symmetrically.

Volume accuracy remains dependent upon ves-sel dimension accuracy and sensor placement. When converting volume to mass, inherent inac-curacies persist due to bulk density variables. But, the improved accuracy of the volume calcu-lation will improve mass calculation accuracy.

Given correct vessel geometry and proper sen-sor placement, you can expect volume accuracy of 3 percent to 5 percent. When combined with a good average bulk density, the accuracy of the mass may be around 5 percent to 10 percent.

Established in 1953, BinMaster makes solid-state point and continuous bin level indicator and control systems and sensor devices.

BinMasterwww.binmaster.comWrite In 504

Left image: Multi-point measurement supports volume calculations.

Shelf after shelf, aisle after aisle, Rice Lake has more than 40,000 items in stock

and ready to ship, same day. Its no secret being the best by every measure takes

service, selection, and speed.

Need it now? Just pick up the phone. Our people are on call

to respond day or night. Let us help put a smile

on your face.

800-472-6703www.ricelake.com

m.ricelake.com

Our Commitment Never Ends

Write In 109

Tank Side CoalescerThe Eriez HydroFlow 15-gallon (56 liter) Tank Side Coalescer removes tramp oil and ines and returns clean, reusable coolant to machine tool sumps and parts washers. This portable unit comes with a 9-foot suction hose and a 5-foot clean discharge hose. The Tank Side Coalescer features a 110-volt electric submersible pump, coupled to an adjustable skimming device which, when installed properly, rests in the sump and collects oil from the surface. The pump delivers skimmed tramp oil and coolant to the coalescer settling tank. A 15-gallon polyethylene drum, an inner oil

diversion bafle, an oil discharge spigot and a clean coolant discharge hose are part of the settling tank. Clean coolant grav-ity lows from the settling tank through the discharge hose and back to the sump. The skimmer can be modiied to work in machine sumps with as little as 3 inches of coolant.Eriezwww.eriez.comWrite In 505

Storage VesselsRoss Storage Vessels are custom-built to meet exact speciications for pressure, temperature, material of construction, cover design, discharge assembly and access ports. The pictured carbon steel vessel, for example, has a full holding capacity of 9,750 gallons and is ASME-stamped for 50-psig internal pressure to full vacuum at 200 F. The elliptical-style top and bottom heads include various size langes and couplings at customer-speciied locations. Internal surfaces were thoroughly cleaned, dried and media blasted; exterior surfaces were also media blasted and coated with red oxide primer. Charles Ross & Son Companywww.mixers.comWrite In 507

Tank Vent Scrubbing SystemBionomic Industries' VentClean Scrubber is speciically designed to scrub storage tank and railcar vent emissions caused by breathing and illing operations. It's the latest edition to Bionomics success-ful ScrubPac family of packaged scrub-ber systems. Due to its unique design, the

versatile VentClean can handle single as well as multiple sources with large variations in venting rates with equally high removal eficiency. VentClean is available in three model sizes L, M and H to handle gas capacities from 0 to 800 acfm. Available in two unique operating conigurations, VentClean easily adapts to a variety of scrubbing liquid preferences.Bionomic Industrieswww.bionomicind.comWrite In 506


10 Tanks & Vessels

WORLDS FASTEST BLENDING AND CLEAN UP

+1-315-797-0090 USA: 1-800-944-6644 [email protected]

No other bulk solids mixer delivers this unique combination of benefits:

n100% Uniform blending and/orliquid additions to 1 ppm in 2-1/2 minutesnTotal discharge with no segregationnUltra-gentle tumbling action(versus blades forced through batch)

nUltra-low energy usagenEqual efficiency from 100% to 5% of capacity nUnlike other rotary mixers: No internal shaft or seals

contacting material Every internal surface accessible Significantly faster washdown Seal changes 10x to 20x faster

ROTARY

BATCH

MIXER

RIBBON/PADDLE/PLOW

BLENDERS HANDLE

POWDERS TO PASTES

Munson Ribbon,

Paddle and Plow

Blenders force

agitators through

stationary materials,

imparting shear

needed to reduce

agglomerates and

blend pastes and

slurries. Choose from

basic, low cost

industrial units to state-of-the-art designs

of 304/316 stainless and exotic alloys with

heating/cooling jackets, liquid spray additions,

high-speed choppers/intensifiers, and finishes

to USDA Dairy and other standards. Extreme

vessel rigidity allows tight agitator-to-vessel wall

tolerances, resulting in a minimum heel of

residual following discharge. Heavy- and extra-

heavy-duty batch and continuous models in

capacities from 1 to 1000 cu ft (.03 to 28 cu m).

VEE-CONE BLENDERS

SANITIZE ULTRA-FAST,

THOROUGHLY

Munson Vee-Cone

Blenders feature

smooth internal

surfaces free of

baffles, shafts and

bearings, allowing

unobstructed material

flow, plus complete

discharge through a

gate valve for rapid

cleaning or sanitizing

of the easy-access interior. Uniform blends are

typically achieved in 5 to 15 minutes with equal

efficiency at fill volumes from 100% to 25% of

capacity. Ideal for dry and granular materials,

these blenders provide a tumbling action that is

gentler than machines that force agitators through

stationary material. Options include spray bars

for liquid additions, Clean-In-Place (CIP) systems,

abrasion-resistant steel construction, ASME-coded

jackets and weigh batching accessories.

FLUIDIZED BED MIXERS

BLEND ULTRA-FAST,

GENTLY

Unlike Ribbon and

Paddle Blenders with

a single agitator shaft,

Munson Fluidized Bed

Mixers feature two

shafts with paddles

that counter-rotate

at higher speeds to

fluidize material,

achieving homo-

geneous blends in

10 seconds to 2 minutes. Low shear forces

minimize friction with little or no degradation and

insignificant heat generation of

Write In 111


As luid-automation users embrace the latest-generation devices, challenges can arise that dont occur with older, high-power-consumption equipment. At issue here are supervisory and leakage currents generated by control-system I/O. Such currents can cause problems when interacting with the latest low-power components, such as solenoid valves and sensors.

We will here review relevant concerns when applying low-power and electronically enhanced solenoid valves within certain con-trol systems; outline and show how to identify the limited set of cases where problems can exist; and suggest solutions, tips and work-arounds to be considered in consultation with suppliers and product manuals.

In process plants, low-power solenoid valves act as pilot valves that open and close larger ball or butterly valves. Theyre also found on control valves, for fail-safe air release, if theres power or air loss. They work by pressurizing or depressurizing associated actuators.

Latest-gen, low-power valves such as those from ASCO Numatics draw only about 0.5 W, as opposed to the previ-ous low-power standard of around 1.5 W. Todays offerings are eficient and accom-modate power-consumption limits imposed by bus networks, backup power schemes and remote locations. All this has been wel-comed by anyone who speciies solenoid valves for oil & gas, chemicals, pharmaceu-

ticals & life sciences, food & beverage or power & steam.

Advances in low-power solenoid valves are not always matched by necessary I/O changes. A mismatch between control system and valve can bring unintended consequences. Where problems do arise, a valve can hang or stay open when it should close, allowing process media low to continue.Tales of the unintended

The potential problem doesnt come into play for most applications using relay-type output controls to operate solenoid valves. However, where the valve is managed by solid-state I/O modules, some users may encounter problems. Equipment speciiers should match the new valves with the right I/O module (or consider other steps, as outlined below) for reliable operation.

Problems that do arise are due to either supervisory or leakage current. Supervisory current is a low-level loop current found on some traditional PLC/DCS output modules. Its part of a diagnostic scheme that module manufacturers devised to verify the presence of open circuits, i.e., that as long as a load is connected to the module, current should low. Only when the load is disconnected creat-ing an open circuit should current draw be zero. So even off, a small amount of current lows for these modules.

Somewhat more common than supervisory

current is problematic leakage current, which is unintended, residual current produced in a modules off state.

Ideally, off should produce zero low. However, in some I/O modules, electrical il-ters that protect against power surges and transient voltage spikes caused by inductive loads leak small amounts of output current. Also, the off-state impedance of some solid-state switching devices is low enough to allow current to low (See Figure 1).

Leakage current is mostly present in solid-state AC applications using triacs. It can also be found in DC I/O modules.Affected low-power valves

Again, low-power solenoid valves are impacted by output module mismatch. A low-power coil operates at a much lower current than a standard solenoid valve. (It thus de-

The latest current concerns How supervisory and leakage currents affect todays low-power solenoid valves

Get me a Check-All!

S I N C E 1 9 5 8

Our spring loaded check valves are

assembled to your exact needs, ensuring

absolute precision and reliability. They

work like they should. Plus, most lead times

are less than one week. Thats what makes

Check-All the only choice.

ITS A CHECK-ALL

Its more than a check valve...

Manufactured in West Des Moines, Iowa, USA 515-224-2301 www.checkall.comWrite In 112 Write In 113

By Manny Arceo and Jack Haller, ASCO

Off-state impedance of some solid-state switching devices is low enough for current to low.

THE PERFECT COMBINATION FOR CRITICAL APPLICATIONS

Our line of check valves, ball valves and screwed or integral bonnet

needle valves can be supplied with either single or double ferrule

fi tting end connections.

Brennans valves are built to withstand heavy impulse and vibration.

The valves are easy to install and tube ends are interchangeable with

other quality brands.

Next time you need brass or stainless steel instrumentation valves,

think of Brennan.

Toll Free: 888-331-1523, www.brennaninc.com

Brennans Instrumentation Valves and Fittings

2014 Brennan Industries, Inc.

DISTRIBUTION CENTERS:

Atlanta Cleveland Dallas Houston

800.458.1988 800.331.1523 800.443.9937 800.443.9937

Los Angeles Seattle Shanghai Toronto

800.942.5321 800.445.7107 +86 021 57390012 800.331.1523

Write In 114


14

Write In 115

Valves & Actuatorsenergizes at a lower current also, termed the drop-out current.) In some cases, a valve with an extremely eficient magnetic design operates with only a few milliamps of current.

Unfortunately, some existing I/O module designs assume solenoid valves might draw as much as 6 to 10 W, and not less than 1.4 W. Any leakage or supervisory current the module emits is below these levels, ensuring the solenoid valve is maintained off, keeping it de-ener-gized.

However, the solenoid valves draw only about 0.5 W. So some output modules may generate a high enough leakage or supervisory current to inadvertently affect valve operation.

Besides low-power valves, two recent electronically enhanced sole-noid-valve types can encounter problems, including those having an option for a charging circuit that stores energy on capacitors. Typically, an I/O module with problematic supervisory or leakage current produc-es enough low to charge up these capacitors, keeping the valve in an undesired energized (open) state.

Another challenge, found on a few electronically enhanced solenoid valves, involves peak and hold pulse-width-modulation (PWM) circuits. This type power-management circuit delivers a higher inrush current to energize the valve, and then reduces power to hold the valve open. Thus power to the valve is switched on and off at a fast pace (i.e., at a high frequency). The longer the valve is kept switched on, the more power the valve consumes.

A PWM circuit has a lower holding mode, reducing power and coil heat rise. However, because holding-power levels are lower than the

standard valve power levels, supervisory and leakage currents can pre-vent proper valve closing.Testing the currents

Supervisory or leakage current wont necessarily impact solenoid valve operation. How do you know whether it is or not?

One simple ield test is an initial indicator for most affected applica-tions. With a normally closed (NC) valve, the problem manifests when the solenoid sticks open, even though the output module is turned off. A user can tap the valve lightly, or slightly lift the solenoid. This helps overcome the magnetic force generated by supervisory or leakage current, releasing the valve core and returning the valve to closed. If a tap or lift allows the valve to shift, a problem probably exists.

To conirm, employ an amp meter or current probe. With the I/O module off, check for current output. If current is detected, its a supervisory/leakage current situation. For modules that pulse current,

If leakage current is less than drop-out current, the valve is not affected.

Rotork Process Controls5607 West Douglas Ave.Milwaukee, WI 53218

phone: 414 461 9200email: [email protected]

www.rotork.com

Redefining Flow Control

Scan this QR codefor more informationabout these products

New Electric OptionsFor Process Control Applications Superior accuracy, low-maintenance, and economical operation. Rotork has expanded its range of control valve actuators enabling virtually EVERY process application to gain the benefits of electric control.

The new Rotork CMA series includes linear, rotary, and quarter-turn control valve actuators that are compact, robust, reliable, and economic. CMA actuators are suitable for most typical continuous modulating applications.

They expand the CVA range of full-featured, non-intrusive, electric control valve actuators, which are installed in thousands of high-value, demanding control valve applications around the world.

CVA ActuatorsQuarter-turnLinear

CMA ActuatorsLinearRotaryQuarter-turn

Write In 116

Write In 117

an oscilloscope will be needed. Where current is discovered, the next step is to determine the valves drop-out current, i.e., at which the valve shifts back to closed.

If supervisory/leakage current is less than drop-out current, valve oper-ation will not be affected (See Figure 2). No further action is necessary.

However, if supervisory/leakage current is greater than drop-out cur-rent, the valve will seem stuck in the open position when de-energized (See Figure 3).

Industry-accepted workaroundsThose with current leakage problems ind the following helpful.

Bear in mind, however, that here not every unique situation can be addressed. Consult the appropriate engineering disciplines and your suppliers for deinitive answers.

In existing installations, for supervisory current, try switching software to passive mode. Digital output modules that use supervisory current often have mode settings. In active, supervisory current lows con-stantly through each output module.

However, should active mode prohibit proper component operation, users can switch to passive. Here current is usually pulsed rather than continually applied (See Figure 4). In this pulsed mode, on time is signiicantly shorter than off time and valve operation isnt affected. Further, on pulse magnitude is lower than the pick-up current. Thus, the solenoid valve will not turn on inappropriately, despite supervisory current presence.

Other I/O modules are conigured so that passive-mode supervisory current only occurs once the valve has been cycled on/off. In this

mode, the I/O module checks for open circuits only when in the on state. Here again, the valve will not turn on inappropriately.

In existing installations, for leakage current, try applying a loading resistor. Unlike supervisory current, leakage current cannot be managed via software settings. Primarily caused by electrical ilters built into the I/O module to guard against electrical anomalies, leakage current is present 100 percent of the time in the off state.

However, PLC and DCS makers often recommend using a loading resistor. With a particular resistance and wattage in parallel with the valve, the resistor absorbs excess current, and ensures that across the valve it remains below the off state drop-out current. This eliminates or limits problematic leakage-current effects. Adding a resistor is by far the simplest solution, especially if the output modules are in a control-room marshalling cabinet.

Maker resistor value and wattage vary depending on leakage magni-tude and voltage. Area classiication (Class I, Division 1 or 2) also affects what is done to limit leakage current effects. Consult the literature or ask the manufacturer for accurate information.

New or upgraded installationsFor supervisory current in new or upgraded installations, select the

right I/O module. For a control-system upgrade, the right output mod-ule helps ensure trouble-free, low-maintenance operation.

If supervisory current is needed as part of a diagnostic scheme to detect open circuit conditions:

Consult the maker for drop-out current of the low-power solenoid valve used.



If leakage current is great enough, the valve will stick in the open position. In passive mode, current is usually pulsed rather than continuously applied.

Theres something diferentthat youre looking for in a material handling system. Sure, you want superior performance. Thats a given. Lets talk about what you dont want:

And heres what Hapman

will get you:

The right system starts with the right people.(And that makes all the diference.)

Boilerplate design

Major customization markups

Diicult parts replacement

Sleepless nights

2014 Hapman. All rights reserved.

MORE THAN EQUIPMENT

We get it.Meet Hapman. Whether

custom-made or custom-matched, all of our systems come with real people who care about

your success.

Your ideal design

Free material testing

Guaranteed performance

Round-the-clock support

For a free test of your material, visit:hapman.com/material-test.

Seamlessly Integrated Bulk Material Load-Out System

Hapman will seamlessly integrate each

piece of bulk material handling equipment to work

as a complete system. This illustration represents

a packaging operation for fertilizer. The two

materials are moved from bulk bag unloaders to

an upper mezzanine with Helix lexible screw conveyors. A third material is transferred from a

storage silo to the mezzanine with a tubular drag

chain conveyor. Each material is precisely metered

with a volumetric feeder to a hammer mill. The

blended material from the mill is carried to a

truck load-out area. This system is completely

automated with integral controls.

For more information on Hapman bulk solids

handling equipment and engineered systems, call

(800) 427-6260, e-mail [email protected], or visit

hapman.com.

Hapman People and Expertise

Tubular Drag ConveyorBulk Bag Unloader Helix Flexible Screw Conveyor

Write In 118


DONT IGNOREPOTENTIAL

HAZARDSIN YOUR FACILITY

PROVEN QUALITY & RELIABILITY FOR NEARLY 70 YEARS

Visit the new FIKE.COM to use our easy online DiscCalc tool

or find an expert in your area

TRUST FIKE RUPTURE DISCS

Comprehensive selection of ASME, CE and 3-A certi ed discs Complete line of products designed for CIP/SIP applications Dedicated team of engineers and technical support

877-814-3453

[email protected]


18 Valves & ActuatorsSelect an up-to-date output module with

supervisory current lower than the valve drop-out current.

If valves are the last components selected, irst choose a compatible output module, with both active and passive modes for detecting open circuits. Operate in passive mode.

If possible, select a module where supervi-sory current is pulsed and always present.

With new or upgraded installations, for leak-age current, select the right module, apply a resistor or try surge suppression.

If supervisory current isnt needed:Consult the I/O module data sheet as to any

current leakage.Consult the valve maker as to drop-out cur-

rent for the valve intended.If leakage current is less than the drop-out,

the valve isnt compromised.If leakage current is greater than drop-out,

connect a loading resistor to the valve. Consult

the literature or manufacturer to ensure the suitable resistor.

Another option is using the surge-suppres-sion version of a low-power coil. Surge sup-pression coils that are not polarity-sensitive contain diodes in series with the coil windings. In some cases, the added power drop across the diodes is enough to keep leakage current from keeping the valve energized.

With new installations, for leakage current, adjust your expectations about coil wattage.

Choosing appropriate coil wattage also ensures proper valve operation with a select-ed I/O module. Once the output module is chosen and any leakage current magnitude veriied, select valves with coil drop-out cur-rent greater than leakage current. Resistors and surge suppressors are unnecessary a preferred outcome, especially for remote upgrades, where adding components after installation is expensive.

Of course, suficiently high leakages effec-tively rule-out use of the latest low-power valves, depriving you of power-savings oppor-tunities. If this is the case, instead of models drawing 0.5 W, consider higher-power valves.

Manny Arceo is principal engineer and Jack Haller is manager of electronics and magnetic at ASCO. Contact them at [email protected].

ASCO Numatics, a division of Emerson, offers luid-automation solutions, including luid-control and luid- power products for industrial applications. The ASCO Numatics product line in North America includes more than 50,000 valves, air-preparation equipment and actua-tion products.

ASCO Numaticswww.asconumatics.comWrite In 508

Call: 800.836.7068

visit our showroom

www.materialtransfer.com Container Discharger Drum Discharger Bulk Bag Filler Bulk Bag Discharger

MATERIAL MASTER

BULK BAG CONDITIONER

World Class Manufacturer Of Material Handling Equipment

PRIOR TO CONDITIONING

DURING CONDITIONING

AFTER CONDITIONING

Safely returns solidi ed materials in bulk bags to a owable state Increase production throughput, and improve plant cleanliness Eliminate lost time accidents caused by unsafe conditioning methods The industries most robust construction and compact footprint Over 75,000 lbs. of conditioning force available, up to 250% more than others Proprietary automation package ensures complete bag conditioning Finite element structural analysis for durability, safety, and dependability Fork lift movable base for ease of installation, shipped fully assembled Custom designed for your application requirements Patented pivoting conditioning arm design eliminates horizontal guide rod and

compression plate de ection found in opposing sheet metal platen units

Write In 121

Off-the-shelf valve automation packages are a better way of doing things

By Bob Donnelly

Valve automation packages have arrived. So why are you still buying components?

Its been the rule for too many years that industrial-valve distributors, and some end-users, separately purchased the valves, actua-tors, mounting kits and other components to assemble and test a valve automation package.

If you still do so, it means requests for quo-tations to each supplier of those same valves, actuators, mounting kits and other compo-nents. Dont forget that it also means each component ships separately not that the logistics of this ever gets mixed up with separate freight and handling charges.

The cost of skilled and semi-skilled labor to

assemble and test the inished assemblies is considerable. So not only is it time-consuming, i.e., the specifying, quoting, ordering and wait-ing on delivery for each separate component, it also entails unnecessary costs.

Margins may improve and the resources-draining exercise deliver a return on invest-ment, but the unnecessary costs mean the pro-ductivity gain isnt what it could have been.

So, again, why still buy components?Today automation packages come from sup-

pliers off-the-shelf. The operational and inan-cial advantages of the approach, assuming combined with the best possible service from the supplier, make it a proverbial no-brainer.

Today, you can get a quotation for anything from a simple actuated valve package to the most sophisticated of conigurations, taking advantage of the latest information technology, data management and automation advances. It will be fully tested when it arrives.

Robert M. Donnelly is the vice president of marketing for Flo-Tite Valves & Controls.

Flo-Tite Valves & Controlswww.lotite.comWrite In 542

The new must have its due

Write In 122

3800 Camp Creek Parkway

Building 2600 Suite 120Atlanta, Georgia 30331

678-553-3400 Fax: 678-553-3459 Email: [email protected]

Areas of application GEM SUMONDO Single-Use Diaphragm Valve

Pharmaceutical, Biotechnology and Cosmetics Industries Medical Systems

Advantages

Proven, reliable actuator design (remains in plant) Mechanically stable and gamma- sterilizable valve body material Hermetic sealing between valve body and actuator Validation Guide available upon request

GEM SUMONDO

controls the world of Single-Use Technology

Write In 123


Write In 124

Write In 125

Globe ValvesThe globe valves in the GEM 505, 507, 550, 554 and 555 series have been tried and tested for use in various main and auxiliary processes for hygienic applications. To com-plete the range of globe valve bodies, an additional design has now also been included. For the valve ranges provid-ed, a stainless steel investment cast body is now available in nominal sizes of DN 15, 20, 25, 40, 50 and 65, with inte-grally cast ASME BPE clamp connections and short ASME BPE length. It can be supplied with an internal and external surface inish of Ra 0.8 up to Ra 0.4.

Toxic Gas Multi-Actuator Valve ControllerMinimize your risk and liability with Halogens Emergency Valve Shutoff Systems. If you use chlorine or other hazardous gases you know the risks associated with them. Halogens Emergency Shutoff Systems provide an extra measure of safety for these environments. The Duplex Model II control system quickly closes up to two Eclipse actuators on toxic gas cylinder and ton container valves when acti-vated by panic buttons or remote gas sensors. The Duplex Model II computer system applies 30 foot-pounds of torque for test closures and 50 foot-pounds of torque for emergency closures of the cylinder valve. All Fire Codes recognize and approve the automatic-closing

fail-safe shutoff valve system in lieu of a scrubber treatment system. With a Duplex Model II, SCADA systems can be provided with actuator closure status and error codes to quickly analyze problems and take the appropriate correc-tive action. When combined with a Halogen Valve gas detection system, you will have a secure facility 24 hours a day.

Halogen Valve Systemswww.halogenvalve.comWrite In 510



GEM is one of the world's leading manufacturers of valves, measure-ment and control systems. Over the course of 50 years, this globally focused, independent family-owned enterprise has established itself in important industrial sectors thanks to its innovative products and cus-tomized solutions for process media control. GEM is the world market leader for sterile valve applications in the pharmaceutical industry and biotechnology industries.

GEMwww.gemu-group.comWrite In 509

Call us todaytoll-free at 855 294 1400

Fast or easy? Why not both?Fast or easy? Why not both?Fast or easy? Why not both?Save time and money as well as increase productivity by using Remote Control's FastPak program.Our FastPak service provides valves, actuators, and accessories in preassembled, ready-to-install packages, which usually ship within 24 hours of your order. The FastPak program offers reliable, high-quality components featuring Remote Control's scotch-yoke pneumatic actuators as well as the Rotork ROM with ROMPak electric actuators. Both packages are available for either modulating or on-off duty. Automated packages for the FastPak program range in size from 1 to 4 with standard NPT end connections. They include a three-piece stainless steel ball valve with RTFE seats and PTFE seals. Special order requirements that include other components are also available.

Fast and EasyValve Automation

Remote Control, Inc.77 Circuit Drive

North Kingstown, RI 02852 phone: 401.294.1400

email: [email protected]

Write In 126


Of available low technology, whats the best for petroleum-industry vent lare-gas mea-surement? The lowmeter thus speciied must measure lows ranging from one foot to 100 feet per second, without restricting low, and all the while accommodate gas composition changes.

Many low technologies work well under predictable process conditions, such as lare safety systems within industrial plants, but upstream vented lare gas can be challenging for those same technologies. It is the authors contention that thermal mass low technology is among the best for these type applications.

First, you may ask, does environmental regulation mandate that oil & gas exploration companies monitor and report daily volumes of lare and vent gas? Yes, its required both onshore or offshore, done either by calculation or direct measurement. And, given legitimate safety, environmental and security concerns, regulation will continue to expand.

In April 2012, the EPA issued rules, 40 CFR Part 98, Sub Part W, to address air emissions from all oil & gas exploration, production, processing and transportation facilities. It says direct measurement of vented-gas low must be done continuously. This ruling has impacted operators in the Marcellus and Utica shale in western Pennsylvania and upstate New York, the Eagle Ford in Texas, the Bakken formation in the Dakotas and others.

Oil & gas factsWhen crude oil is extracted from shale for-

mations, a considerable amount of natural gas is entrained, and this gas rises to the surface. A decade of North American shale oil & gas exploration and extraction has led regulators

to clamp down on emissions, enforcing rulings to ensure compliance.

Flares seen in oil ields are burn-off from various sources. One is inal-product vent gas from production tanks, sometimes referred to as tank batteries, which hold stable product for truck loading. The tanks are at atmosphere and venting allows product low in and out. Vapor vented must be captured and burned. Given the potential for air to low back into systems, it cant be injected into the pipeline as re-pressurized gas.

High-pressure aspects of the production process lead to further laring. As crude oil, natural gas and water come out of a well, pressures can range from 100 PSI to 5,000 PSI. Water and gas are separated from the crude oil. The gas is lowed upstream for further pro-cessing.

The gas is pressurized, typically, and vola-tiles are driven off, but the gathering system infrastructure still requires a lare to burn off hydrocarbons rather than vent to atmosphere. A pipe feeds gas to the lare stack.

It may be necessary to lare gas during drill-ing, production or processing for several other reasons. When any shale well is drilled and fractured, a temporary lare for well-produc-tion testing monitors gas and oil pressure, low and composition. Flaring lasts several days or weeks, as the well liquid and gas pres-sures and lows are stabilized.

Vent & lare gas metering in the oil & gas industry


By Jerry J. Boisvert

It is the author's contention that thermal mass low technology is very suitable for upstream vented lare gas applications.

Thermal mass flow technology seen as suited for unpredictable process conditions

2014. Micro Motion, Inc. All rights reserved. The Emerson and Micro Motion logos are respective trademarks and service marks of Emerson Electric Co. and Micro Motion, Inc.

Were throwing away money repairing and calibrating old flow and density meters. I need a reliable technology that eliminates routine maintenance and helps me improve my plant performance.

Easy to install, minimal cost to maintain and superior measurement delivers the

results you need. Volumetric meters have moving parts that can wear down.

Plus, they require additional pressure and temperature devices to convert measurements to mass or standard

volume. A single Micro Motion Coriolis meter and density meter measures liquids, slurries and gases for direct

mass flow, volume flow, liquid density and temperature. With meters installed in nearly every conceivable

application, you can count on expertise and performance that will help you save and make money.

Learn more at: www.EmersonProcess.com/MicroMotion

YOU CAN DO THAT

Write In 129


26

Write In 130

FlowmetersIn a well-site extraction, for a typical pad of

six wells, each pad has a lare-stack pipe two inches to six inches in diameter. In the gas-extraction process, gas laring at the stack must be monitored and recorded. Federal, state and local agencies require the daily low of vented gas at the lare inlet be totaled so as to better understand and control the release of volatile organic compounds (VOCs).

As already mentioned, the best lare-gas low-meter choice measures an unrestricted low trav-eling from one foot to 100 feet per second and accommodates changes in gas composition.

Flare line lowsThe lare line gas can be of varying composi-

tion with hydrocarbons from C2 through C6. Composition can change based upon what happens at the extraction point. The gas low is low under stable, normal conditions. Upset conditions can cause low velocities to increase up to as much as 300 feet per second. This wide rangeability of low, including pressure drops and varying gas compositions, can be a showstopper for most low technologies.

One low measurement method that per-

forms reliably and accurately in vent lare-gas applications is thermal mass technology, which operates on the constant-temperature differ-ential method and provides a direct mass low rate measurement, i.e., standard volumes with-out pressure/temperature compensation.

Of two RTD sensors, one measures tem-perature and the other senses low. Changing gas temperature is corrected for and the low-sensor temperature is set precisely above that of the passing media. Flow-measurement accu-racy is based on the fact that any media will conduct heat off the sensor at a rate directly related to the mass low rate.

Thermal mass technology has been around many years, and sensor design and electronics have improved measurably.

Given the various vent lare-gas stream con-stituents, its important to have a probe that is of single-piece construction and easily main-tained. Quick response to low changes is essen-

tial to support normal velocities of two feet to eight feet per second and up to more than 100 feet per second during upset conditions.

When pressures dropAnother challenge involves pressure drops

that occur as vent gas lows through the lare line. This variation can challenge low technolo-gies unless they are calibrated for upfront.

Vented lare-gas monitoring technology must effectively respond to pressure changes or drops, and support turndown ratios up to 100-to-1. Thermal mass technology excels here. Further, thermal mass lowmeters present no low-stream obstruction and accommodate vir-tually any line size. Thermal mass technology is easy to install using a process thread of NPT and, possibly, a hot-tap assembly. Either way, installation is quick and start-up and com-missioning cost low.

A handful of low technologies measure vent lare-gas lows, including Pitot tubes, oriice plates with pressure transmitters, mechanical turbine style, thermal mass and a few others. Mechanical lowmeters, like turbines, have seals and bearings that can wear out over time.

In the gas extraction process, gas laring at the stack must be moni-tored and recorded.

Bulk Bag Discharging

Visit: nbe-inc.com Call: 616.399.2220 Email: [email protected]

DIS

CHAR

GE

M

OVE

M

IX

STO

RE

FILLW

EIGH

Bulk Material Conveying

Bulk Material Mixing & Blending

Bulk Material Storage

Bulk Bag Filling

Bulk Material Weighing

System Profile:

A fully automated material handling system for the conveying and sorting of highly fragile food product.

12,000 lbs./hr. of material are vertically conveyed in totes, tilt unloaded, and laser sorted through 2 stages.

Sorted product is conveyed into storage totes; totes are weighed to NTEP-certified weights of +/- .01%.

System Profile:

An integrated bulk mixing operation to blend multiple, sluggish materials for downstream supply.

Process stages include: gaylord dumping, vacuum transfer to mixer, high-volume mix, process supply.

Stringent process recipe parameters require reliable, accurate supply of thorough, homogenous blend.

System Profile:

A self-contained material transfer station for the re-packaging of material for inventory or processing.

Free-flowing material is re-packaged from bulk bag to tote, or tote to tote, depending on process need.

Custom discharge/fill assembly speeds container mating, eliminates material contamination and dusting.

System Profile:

A complete bulk bag filling process; fills (12), 2,000 lb. bags/hr.; bulk material is irregular and cohesive.

Process stages include: pallet feed, bulk bag filling, material metering, weighing, and outfeed conveying.

Operator interaction; optimal physical ergonomics, are essential to ensure total process optimization.

System Profile:

A self-contained, automated reclamation system for transfer, metering, and converting of metal flake.

Multiple, highly abrasive, non free-flowing, metal flake materials enter system from separate hoppers.

Material supply to briquetter occurs through three infeed lines; feed rates are controlled by weight.

Performance-proven Construction:

4-1/2 bore hydraulic mast cylinder and load-rated lifting mechanism lift tote to 23-foot unload height.

2-stage, high-speed image sorting ensures material maintains original characteristics during processing.

Reverse-tilt filling uses optical sensors to ensure material load drop distance does not exceed 5 inches.


2,500 lb.-capacity dumper with dust-tight, custom hood; dual hydraulic lifts for high-speed duty cycles.

Material transfer hopper, with integrated pull-style agitator, pre-conditions material prior to mixer feed.

10,000 lb./hr. blend rate mixer; custom broad-throw paddles and auger infeed scoops reduce cycle times.


4,000 lb.-rated framework capacity; 304-2b stainless steel, continuous-weld material contact surfaces.

Air-actuated discharge/fill assembly automatically aligns tote flanges/inlets; speeds material transfer.

Integrated weigh system signals control valve to meter material flow; fill weight accuracy to +/- 1.0 lbs.


Pneumatic actions bring illhead and rear bag hooks well into operator reach for ideal operator posture.

8 GPM hydraulic fillhead lift; safe and fast fill cycles exceed speed and weight capacity of ball screw style.

20-pallet magazine extends operating time between reload; reduces operator interaction, labor allocation.


Large-capacity, V-shaped hopper with integrated, 9-inch, variable frequency drive, live bottom discharge.

40 incline, 29-foot run, boxed-cleat conveyor; 3 HP, TEFC gearmotor and VFD drive; 60 FPM drive speed.

Material-specific loss-in-weight feeders, with variable frequency drives, ensure accurate downstream feed.

Integrated Automation:

Process controls and automation, designed and built by NBE, are integrated to central controls architecture.

Optical sensors limit material drop distance to less than 5 inches per 150 rotation during tote unloading.

NTEP-certified weigh system, integrated to controller, assures filled tote weight is accurate to +/- .01%.


NBE integrated automation controls supply container dumping, mix auger sequencing, and level sensing.

UL listed control panel and HMI, designed and built by NBE, centralize process operations and reporting.

Rigorous NBE risk assessment procedures worked to prevent hazards and improve physical ergonomics.


A single, menu-driven HMI, designed and built by NBE, simplified operation, reduced labor allocation.

NBE integrated automation optimized bulk storage stage from commodity to process-critical operation.

Sensor-actuated valve controls, with bulk and dribble flow settings; ensured fast and accurate tote filling.


NTEP-certified, automated bulk bag filling with weigh accuracy to +/- .01%; operator-monitored from HMI.

Bag densification cycle intensity and frequency are operator-controlled from the central system HMI.

High-speed, system-wide process communications and monitoring from UL listed panel, built by NBE.


Process automation and controls, designed and built by NBE, integrate with existing system architecture.

NBE expertise identified, applied, and met applicable equipment codes, standards, and regulations.

Automated weighing provides assurance that metered weights are accurate; improves reliability.

System Profile:

An integrated process solution for dust-free handling of severely agglomerated, caustic, dry powder.

Processing requires bulk bag unloading, material conditioning, and transport to downstream mixer.

Closed-cycle design, from bag unloading to mixer discharge, eliminates dusting and protects operator.


6x4x5/8 tubing exceeds ASME B30.11-2004 for bag weights to 4,000 lbs.; heavy gauge sheet and plate.

Integrated bag conditioning uses hydraulic paddles and rams for up to 28,000 lbs. of bag impact force.

304-2b stainless steel conveyor with food-grade, flex-trough bottom; 18,000 lbs./hr. transfer rate.


All process controls, sensing, monitoring, and reporting integrate to a UL listed panel, designed and built by NBE.

NBE automation engineering integrated legacy upstream and downstream equipment to the central NBE HMI.

Rigorous NBE risk assessment procedures reduce operator hazards; improve physical ergonomics.

nbe-inc.com/automate

Watch this equipment in action: nbe-inc.com/storage

Watch this equipment in action: nbe-inc.com/fillers

Watch this equipment in action: nbe-inc.com/weighing

Watch this equipment in action: nbe-inc.com/dischargers

Watch this equipment in action: nbe-inc.com/convey

Watch this equipment in action: nbe-inc.com/mixing

Watch all 19 NBE equipment profiles in action at: nbe-inc.com/automate

Write In 131

Further, if media lowing through the turbine section has any particulate matter, a turbine lowmeter can foul. The same is true for any meter having an entry point, such as an oriice plate, which can potentially clog.

At wellheads vent gas can be laden with sulites and other lare-line particulates. A single-piece constructed probe body without openings or multiple sensor prongs is a huge beneit in dealing with fouling media.

Other technologies, inal wordsAt close, it needs to be fully understood

that laring is a controlled burning of natural gas produced in association with oil in the course of routine oil and gas production opera-tions. The purpose of venting is a controlled release of unburned gases directly into the atmosphere. The availability of a lare or a vent ensures that associated natural gas can be safely disposed of in emergency and shut-down

situations. There are some newer methods in the oil and shale ields which can re-utilize this exhaust gas, but these methods are very costly, and sometimes technical unfeasible.

From a low measurement perspective, there are some newer lowmeter technologies, like transit-time ultrasonic and Coriolis, which can perform well in vent & lare gas applications. However, their price point is typically higher than for thermal mass lowmeters. On the other hand, oriice plates with pressure transmitters and Pitot tubes can measure nominal or upset condition lows, but during the occasional upset condition, the wide dynamic low range will prove dificult for these technologies to manage. In addition, gas mixture deposits can cause plugging problems with oriice plate and Pitot tube measurement device espe-cially with sulites in the gas.

The use of thermal mass low technology offers the end-user the lexibility of a wide turndown ratio on the low range, and can accommodate the variance in gas composi-tion. Whether the gas lare is a remote well site or a compressor station, the thermal mass design can be line powered (AC or DC) or it can be solar powered and wireless in its output. When one looks at the typical vent gas lare at a wellhead site, all lows are typi-cally below velocities of 300 feet per second with the high end measurable by thermal mass meters and even ultrasonic lowmeters. However, many lares are speciied based on worst-case scenarios that exceed this scale of measurement. Other low technologies for vent lare gas applications may require mul-tiple measurement techniques, increasing cost and often requiring more than one lare-line opening.

All things considered, this author believes thermal mass low technology offers an opti-mal and economical solution for vent & lare gas measurement.

Jerry Boisvert is the sales and marketing director for Thermal Instrument Co. and has worked in level and low instrumentation mar-ket for more than 30 years, including with Siemens, Emerson Process, Magnetrol, Flexim, and others. Reach Boisvert at (215) 355-8400 or [email protected].

With more than a half-century of provid-ing best-in-class low measurement technol-ogy, Thermal Instrument Co. of Trevose, Pennsylvania, says it has solved just about every low measurement challenge imaginable with its thermal mass low metering technology.Thermal Instrument Co.www.thermalinstrument.comWrite In 511

Write In 133

Write In 132

800-601-5949 t 630-365-9403 t www.monitortech.com t www.flexar.infoBlog: monitortech.typepad.com t E-mail: [email protected]

Do i ng Ou r D o i ng Ou r L e v e lL e v e l B e s tB e s t

FlexarFlexar

Guided wave radar real-time level

SiloPatrol

Smart plumb bob

SiloTrackTM

Inventory software

To Measure & ProtectWho wants to climb silos?

It costs time and can present safety issues.

Monitor Technologies level sensors provide a wide variety of solutions including:

Some offerings include:

n Continuous level measurement and inventory managementn High, low and/or intermediate point level indication of stored materialsn Provide silo overfill protectionn Turn on or off other processes based on the detected

presence or non-presence of material

SafePoint

Truly fail-saferotary paddle

TrueCap MK-2

RF Capacitance withpush-button calibration

Ideal for overfill protection


28Flowmeters

Write In 134

Write In 176 Write In 177 Write In 178

Write In 179

Write In 180

Write In 181

Clamp-on Doppler FlowmeterGreyline's new DFM 5.1 Doppler Flowmeter employs the lat-est technology in Doppler signal processing to measure low from outside a pipe. Faster, cleaner processing, greater data resolution and an improved ability to ilter out noise all combine to produce data accuracy far greater than previously possible, Greyline says. The clamp-on ultrasonic sensor mounts on any -inch ID or larger pipe. The DFM 5.1 is designed for dificult liquids like wastewater, sludge, slurries, abrasives or any liq-uid with bubbles or suspended solids. Calibration and start-up is simple with the built-in ive-button keypad. Greyline Instruments, Inc.www.greyline.comWrite In 513


30 Flowmeters

Write In 135

Inline Ultrasonic FlowmeterThe Sonic-Pro S4 inline ultrasonic

lowmeter features low mea-surement technology with no mov-

ing parts, and no internal liners

to wear out. The S4 Inline pipe ittings facilitate installa-tion of the meter. The lowmeter uses the Transit Time method to measure water low. A special low-power mode permits operation with battery for limited functions. Optional advanced data communication protocols include Industrial Ethernet, Modbus RTU, Modbus TCP, PROFIBUS TPV1 and PROFINET. Download data logging iles directly to a lash drive via USB. Dual relays for rate alarms, total alarms or proportional feed control.Blue-White Industrieswww.blue-white.comWrite In 516

Non-intrusive Gas and Liquid Flow Measurement in Harsh, Corrosive EnvironmentsFLUXUS F/G 7407.316 SE ultrasonic liquid and gas clamp-on lowmeters allow for an inherently precise bi-directional, highly dynamic low measurement of volume and mass low rates of virtually any gaseous and liquid media even at wet gas applications (up to a Liquid Volume Fraction of 5%) or liquid media carrying high contents of solids. With the transmitter being FM Class I, Div. 2 certiied transducers for FM Class I, Div. 1 and 2 are available it is also the ideal

lowmeter for hazardous areas. Moreover, with its stainless steel enclosure (316L / 1.4404) it is corrosion-resistant and especially suited for applications offshore.FLEXIM Americaswww.lexim.com/usWrite In 517

One Contractor Saved $40 Million on a $400 Million Project

2014 Bentley Systems, Incorporated. Bentley, the B Bentley logo, and ProjectWise Work Package Server are either registered or unregistered trademarks or service marks of Bentley Systems, Incorporated or one of its direct or indirect

wholly owned subsidiaries. Other brands and product names are trademarks of their respective owners.

*CII Research Team 272 - Enhanced Work Packaging: Design through WorkFace Execution.

It could save you 10%. Research by CII and COAA demonstrates that using working packaging soft-

ware on industrial construction projects can reduce risk, increase safety, and decrease total install

cost by up to 10%.* Bentleys ProjectWise Construction Work Package Server is the only solution in

the industry that powers these validated industry-standard processes. With consolidated construction

information, automated work packaging tools, and real-time project reporting and insight,

ProjectWise Construction Work Package Server provides the control you need to increase visibility,

ensure consistency, and delivery predictability.

To download a FREE WHITE PAPER summarizing the CII work packaging research, visit www.bentley.com/WorkPackageServer

What will work packaging

do for you?THE YEAR IN

INFRASTRUCTURE

2014 CONFERENCE

NOVEMBER 4 - 6, 2014

HILTON LONDON METROPOLE

LONDON, UK

Write In 136


Signed into law late in 2013, the primary objective of the Drug Quality and Security Act (DQSA) is to better identify and trace down to the package level certain prescription drugs distributed in the U.S. The results will protect consumers from potentially dangerous pharmaceuticals, including those counterfeit, stolen, contaminated or otherwise harmful.

Under section two of the DQSA, the Drug Supply Chain Security Act (DSCSA) outlines steps that build an electronic, interoperable system to identify and trace drugs through the U.S. distribution supply chain. By 2023, manu-facturers must be able to identify products via unique codes that can be read electronically, traced and used to verify the product, thus providing the tools for increased supply chain visibility.

In anticipation of meeting the require-ments of the DQSA and DSCSA, product brands, contract manufacturers and distribu-tors are working with the U.S. Food and Drug Administration (FDA) to establish track and trace programs to comply with these regula-tions. At the forefront of these programs is serialization, a process deined by the mark-ing of non-predictive serial numbers or unique identiication codes on each packaging unit.

The serial number can be used to trace prod-uct across the supply chain, thwart diversion and counterfeiting and help protect the secu-rity of U.S. consumers.

Diversion, counterfeiting and recallRegional economies are more and more inte-

grated through new marketplaces, increased

trade and globalization. The Internet is a prime source of falsiied drug sales. Over 50 percent of products purchased on the Internet are counterfeit. These factors make it easier for counterfeiters to trade and transport falsiied dugs. Having a way to combat counterfeiting is paramount in todays global economy.

Giving all parties involved in the supply chain full visibility, as well as having updated data-base management with aggregation informa-tion, means there is immediate insight into where the product sits in the supply-chain pro-cess, thus reducing diversion and counterfeit-ing risks.

For the pharmaceutical industry, aggrega-tion helps manufacturers deine the relation-ship between single units, such as bottles, with cases and pallets. This system allows the receiver of the product to scan a single code and identify the exact contents of the entire shipment. As a company builds aggregation transactions, accuracy plays a crucial part in its success, and technology such as scanners and high-resolution cameras are critical to the process to capture product codes and ensure product legitimacy.

In addition to establishing successful anti-counterfeiting measures, track-and-trace pro-

Use track and trace to meet drug supply chain security regs Secure the pharmaceutical industrys future with marking technologies that support regulatory compliance

Disinfect Chemical Metering Skids

Stop treating the symptoms and fix the problem.

Progressive cavity pumps have virtually no pulsation

and wont vapor lock or require a gas off valve.

seepex offers engineered metering systems complete

with controls and frameworks for floor or wall

mounting. Our progressive cavity pumps are superior

in quality, performance, service life and operating costs.

Contact us today to find out more.

seepex Inc.

511 Speedway Drive [email protected]

Enon, Ohio 45323 www.seepex.com

Write In 137

www.greyline.com

[email protected]

888-473-9546 / 315-788-9500

Non-Contacting Flowmeter

Measure Flow fromOutside a Pipe

For difficult liquids likewastewater, slurries,abrasives and liquids withbubbles or solids

Works on metal orplastic pipes diameter or larger

Measures and totalizesforward and reverseflow

Sensor rated for Div.2 hazardous locations

DFM 5.1 DopplerFlow Meter

Write In 138

By Jim Kerper

In addition to establishing successful anti-counterfeiting measures, track-and-trace programs deter activities such as charge backs and diversions. (RCarner/iSTock-photo/Thinkstock)

REGISTER NOWMake THE Water Quality Event YOUR Water Quality Event!

WEFTEC is the premier water quality event of choice for thousands of professionals looking for water quality solutions and the latest innovation.

Highest value WEFTEC is priced lower than any other water quality show of its kind

Highest-quality, most-comprehensive educational content, featuring: more than

115 sessions, 31 workshops, 8 facility tours,

mobile sessions, and exhibitor showcases

Largest water quality exhibition in the world, with nearly 1,000 exhibiting companies

Specialized pavilions in the exhibition, including: Stormwater Pavilion, Innovation Pavilion

and more than six Country Pavilions

A show within a show Stormwater Congress, open to all WEFTEC attendees

www.WEFTEC.org

Where the Greatest Minds in Water Meet

Experience what WEFTEC has to offer.

87th Annual Water Environment Federation Technical Exhibition and Conference

New Orleans Morial Convention Center | New Orleans, Louisiana USAConference: September 27 October 1, 2014 | Exhibition: September 29 October 1, 2014

Write In 139


34

When the pressure is on,insist on a Fairchild solution.When the pressure is on,

insist on a Fairchild solution.

TFX17850Low Emission Transducer

Model 4850Cv 5 Volume Booster

Model 63Filter Regulator

Rotork Fairchild has expanded its valve actuation product line to provide broader Cv flow ranges, higher accuracy, lower emissions, and user-friendly tuning capability, in rugged and reliable pressure control products. The new SIL 3 rated Rotork Fairchild 4850 Booster features easy tuning while in service and a Cv of 5 in both forward and exhaust modes. Likewise, the Model 63 Filter Regulator features 5 micron filtration with high flow, while the Low Emission TXFI I/P Transducer provides up to 0.15% accuracy with consumption of less than 5 SCFH, even with natural gas media.

www.fairchildproducts.com

phone: 800 334 8422email: [email protected]

Rotork Fairchild3920 West Point Blvd.Winston-Salem, NC 27103

Call us today to explore aFAIRCHILD pressure solution!

Write In 140

Processing - August 2014

Documents

Transcript of Processing - August 2014