Food

Processing
Maximize thermal efficiencies
by considering fluid viscosities

Also Inside

Storage tank
overfill protection

Prediction method for

centrifugal compressor
performance

3D metal printing for

flow sensors

FEBRUARY 2019 • Vol. XXIV, No. 2

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 AHR EXPO
PREVIEW
Page 28

FLUID
Density
The effects of
temperature and
pressure

Also Inside

Automating custody transfer

level measurements

Ultrasonic flowmeters for

HVAC monitoring

Performing a storage
tank risk assessment

JANUARY 2019 • Vol. XXV, No. 1

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Table of Contents | February 2019 • Vol. XXV, No. 2

Cover Story
12 Heating solutions for food processing
By Matt Hale, HRS Heat Exchangers
Thermal efficiencies can be maximized when the type
of process and fluid viscosities are considered.

Features
15 A systemic approach to overfill
protection
12
By AnnCharlott Enberg and Lydia Miller,
Emerson Automation Solutions
Today’s technologies can point out weak links
when monitoring the condition of liquid
storage tank safety systems.

18 Prediction of centrifugal compressor

performance in off-design condition
By Massimiliano Di Febo and Pasquale Paganini, IPC
This general method and calculation tool can be used
15 26
to evaluate compressor performance.

23 Using 3D metal printing for flow and Departments

pressure sensors
By Doug Sparks, M2N Technologies 4 From the Editor
Quality standards will be required for the adoption of
additive manufacturing of flow and pressure meters 6 News & Notes
using related corrosion-resistant alloys.
10 Application Corner & Quiz Corner
26 Case study: OEMs outsource critical
aspects of fluid handling systems
29 Trade Shows & Events
By Jeff Elliott 30 Featured Products
Leading OEMs turn to contract manufacturers that can
combine engineering, manufacturing and supply chain 31 Advertiser Index
expertise to deliver complete systems that lower costs.
32 FlowControlNetwork.com
Cover: EduardHarkonen/iStock

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2 | February 2019 Flow Control

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From the Editor
A
s you may have guessed — from
the tomato sauce on the cover —
we’ve focused on the food and
beverage industry in this issue of Flow
Control. According to a report from
Markets and Markets, the food and bev-
erage processing equipment market was
valued at $52.37 billion in 2017 and is
projected to reach $74.44 billion by 2023,
growing at a CAGR of 6.1 percent from
2018. One driving factor of the market
is production efficiency, processing time
and quality of food products. Equipment
such as homogenizers, heaters and ovens
consume high energy and power, so food
and beverage manufacturers look to find
ways to lower their energy costs.
One such solution is discussed in this
issue’s cover story by Matt Hale with
HRS Heat Exchangers. He discusses
how choosing the right heat exchanger
for processing types and fluid viscosities
Jeff Jennings: Equilibar LLC | Mitch Johnson: JMS Southeast | Gobind Khiani: Fluor Canada Ltd.
Jim Lauria: Mazzei Injector Company | John Merrill, PE: EagleBurgmann Industries
Steve Milford: Endress+Hauser U.S. | Tom O’Banion: Emerson Automation Solutions
David W. Spitzer, PE: Spitzer and Boyes LLC | George Weihrauch: ABB Motors & Mechanical
Andrew Yeghnazar: Blacoh Fluid Control | Jesse Yoder, Ph.D.: Flow Research
4 | February 2019
VICE PRESIDENT & GROUP PUBLISHER
MICHAEL C. CHRISTIAN
mchristian@endeavorbusinessmedia.com
EDITOR IN CHIEF
MOLLY ROGERS
mrogers@endeavorbusinessmedia.com
can maximize thermal efficiencies. You’ll
also read about fluid viscosities in David CONTRIBUTING EDITORS
AMY W. RICHARDSON
Spitzer’s Quiz Corner, which has been
arichardson@endeavorbusinessmedia.com
given a fresh new look. MARIE MCBURNETT
In our feature section, you’ll find an mmcburnett@endeavorbusinessmedia.com
article from authors at Emerson Automation GROUP ASSISTANT EDITOR
Solutions on monitoring liquid storage DANIEL GADDY
tank safety systems. Next, a technical dgaddy@endeavorbusinessmedia.com
paper by authors at IPC presents a gen- COLUMNIST
eral calculation tool using Cmap software DAVID W. SPITZER
ART DIRECTOR
for the prediction of centrifugal compres-
JULIE WHITTY
sor performance in off-design conditions.
PRODUCTION MANAGER
We also bring you an article on 3D AMANDA PORTER
metal printing for flow and pressure aporter@endeavorbusinessmedia.com
sensors. As Doug Sparks with M2N DISTRICT MANAGER
Technologies discusses, additive manu- JAY HAAS | 205-572-1058
facturing offers benefits when it comes jhaas@endeavorbusinessmedia.com
to prototyping and low-volume products, ACCOUNT MANAGER
and it’s poised to affect flow control ADDISON PERKINS | 205-861-5303
aperkins@endeavorbusinessmedia.com
products. Learn more about the mate-
NATIONAL ACCOUNTS MANAGER
rials being used and current standards
JIM SEMPLE | 908-963-3008
for quality. jsemple@endeavorbusinessmedia.com
Lastly, read how OEMs partnered with ACCOUNT MANAGER
Aztech Controls to outsource complete LISA WILLIMAN | 205-332-5915
systems with two case examples. lwilliman@endeavorbusinessmedia.com
I hope you enjoy reading this issue of DIGITAL BUSINESS DEVELOPMENT MANAGER
Flow Control. MICHAEL RING | 347-365-0641
mring@endeavorbusinessmedia.com
MARKETING MANAGER
Sincerely,
NICK PHILLIPS
DIGITAL OPERATIONS MANAGER
MARY BETH ROMANO
AUDIENCE DEVELOPMENT MANAGER
Molly Rogers ANNA HICKS
mrogers@endeavorbusinessmedia.com SUBSCRIPTION & REPRINT REQUEST
@FlowControl_Mag flowcontrol@omeda.com
CORPORATE TEAM
CHIEF EXECUTIVE OFFICER
CHRIS FERRELL
CHIEF OPERATING OFFICER
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PATRICK RAINS
EXECUTIVE VICE PRESIDENT
SCOTT BIEDA
Flow Control
 MULTIPLE INDUSTRIES
THREE BRANDS
ONE POWERFUL NETWORK

ProcessFlowNetwork.com
News & Notes
Company news
ITT Engineered Valves
earns certification
ITT Inc. announced that select Fabri-
Valve knife gate valves and cylinder
models, marketed by its Engineered
Valves brand, have earned certifica-
tion to IEC 61508 in compliance with
the International Electrotechnical
Commission standards. The IEC listing
for Engineered Valves covers the knife
gate valves and cylinder models that
are manufactured at ITT’s Engineered
Valves’ Amory, Mississippi, operation.
Functional safety is a key focus of the
IEC 61508 certification and is part of
the overall safety that depends on a sys-
tem or equipment operating correctly in
response to its inputs. It is a concept
applicable across all industry sectors
especially the oil and gas industry,
nuclear plants and the machinery sec-
tor where Engineered Valves products
are used.
Rawson and Azbil North
America enter distribution
partnership
Rawson, an ERIKS company, signed a
distribution partnership with Azbil
North America (formerly Yamatake).
The agreement enables Rawson to sell
and service Azbil’s portfolio of indus-
trial automation and control products
in Arkansas, Louisiana, Oklahoma and
Texas. Specializing in simple-to-com-
plex valve and flow product solutions,
Rawson provides solutions designed to
ensure accurate, consistent and reli-
able flow measurement, regulation and
control processes. By partnering with
Azbil, Rawson gains access to products
such as pressure transmitters, electro-
magnetic flowmeters and temperature
transmitters.
Trust Automation and
Cynash partner on industrial
cybersecurity solutions
Trust Automation Inc., a supplier of
automation technology for defense
and industrial applications, has part-
nered with Cynash Inc. to develop a
6 | February 2019
next-generation cybersecurity platform
that can detect and mitigate cyberat-
tacks on industrial control systems that
run critical energy, water, transportation
and industrial infrastructure. The plat-
form builds upon Cynash’s SerialTap,
a patented hardware sensor that pas-
sively monitors the serial communica-
tions used by the majority of the world’s
industrial control systems. SerialTap can
now pass the monitored network traffic
to Trust’s Autonomic Intelligent Cyber
Sensor (AICS), a machine learning sys-
tem that employs autonomic computing
techniques, fuzzy-logic algorithms and a
service-oriented architecture to identify
and counter malicious network traffic
in real time.
Schneider Electric signs
partnership deal with
Transpara
Schneider Electric signed a global OEM
and distribution partnership agree-
ment with Transpara. With Schneider
Electric’s EcoStruxure IIoT capabilities
and Transpara’s Visual KPI solutions, the
partnership will aim to help customers in
operationally intensive industries better
understand and control the performance
of their equipment. Company officials say
customers will be able to quickly under-
stand and eradicate unplanned downtime,
make their processes more efficient and
safely drive measurable improvements to
the profitability of their operations.
Emerson acquires Advanced
Engineering Valves
Emerson acquired Advanced Engineering
Valves (A.E. Valves). The transaction
will enable Emerson to provide its cus-
tomers with Advanced Engineering’s
portfolio of valves to improve process
performance and reliability. A.E. Valves
produces and designs special industrial
valves for the LNG industry, as well as
oil and gas, chemical and petrochemi-
cal customers.
The Witte Company
celebrates 80th anniversary
Process equipment manufacturer The
Witte Company is celebrating its 80th
anniversary. The company produces vibra-
tory fluid bed dryers, coolers, classifiers,
screeners and other machinery.
Siemens gains
IEC 62443 certification
for secure system
integration services
Siemens gained TÜV SÜD certification
for the secure system integration of pro-
cess automation and drive solutions in
compliance with the international IEC
62443-2-4 standards. The integration
projects, verified on the basis of two
standard solutions in the oil and gas
processing industry and in a waste incin-
eration plant, have been certified in con-
formity with IEC 62443-2-4 and -3-3 and
were implemented using the Simatic PCS
7 process control system. The projects
involved process automation, drive solu-
tions and comprehensive security mea-
sures and functions designed to deliver
secure plant operation.
Rockwell Automation
receives IEC 62443
security certification
Rockwell Automation’s security develop-
ment life cycle (SDL) approach is now
certified to meet the IEC 62443-4-1
security standard. Rockwell Automation
is using the certified SDL at all global
development locations to support the
development of all hardware and software
products. TÜV Rheinland performed the
independent certification of the Rockwell
Automation SDL.
AOAC-RI certifies Hygiena
UltraSnap Surface ATP Test
Safety and sanitation testing firm
Hygiena’s UltraSnap Surface ATP Test
gained certification from the AOAC
Research Institute, a product certifica-
tion group. The UltraSnap Surface ATP
Test is used for identifying the possible
presence of microbial contamination.
As required for AOAC-RI certification,
Hygiena used a third-party laboratory
to test the results of UltraSnap on stain-
less steel surfaces in five food matrices,
essentially reproducing a food process-
ing facility.
Flow Control
PTDA Foundation recognizes
Motion Industries VP
Motion Industries’ Ellen Holladay, senior
vice president and chief information offi-
cer, was named recipient of the 2018
PTDA Foundation’s Wendy B. McDonald
Award. Each year, the PTDA Foundation
recognizes a woman who has estab-
lished herself as an integral contributor
to her company’s success and someone
who has brought positive change to the
power transmission/motion control indus-
try. Holladay joined Motion Industries
in 1990 as manager of systems plan-
ning. The award is named after Wendy
B. McDonald, a former PTDA member
who served more than 60 years as a
leader in her family-owned international
industrial distribution company, BC
Bearings Engineers Limited, now a Motion
Industries company.
People news
Badger Meter CFO to retire
Badger Meter’s vice president of
finance, Richard E. Johnson, will retire
effective early April 2019. Johnson
has been succeeded by Robert A.
Wrocklage. Johnson will stay on as
senior vice president of administra-
tion, continuing to assist in the tran-
sition before retiring. Badger Meter’s
vice president-controller, Beverly L.P.
Smiley, will also retire effective in late
March 2019. Smiley has 46 years of
service to Badger Meter. The past 22
years included controllership and prin-
cipal accounting officer responsibilities.
MFG Chemical promotes EHS
director to VP of operations
MFG Chemical, a specialty and custom
chemical manufacturer, promoted Barry
Lassiter to vice president of operations,
responsible for MFG’s three plants in the
Dalton, Georgia, area and the recently
acquired plant in Pasadena, Texas.
Lassiter came to MFG in 2014 following
nearly 40 years with Dupont and Invista to
serve as director of environmental, health,
safety and security. Taking Lassiter’s pre-
vious role is Joe Welch, who joined MFG
early in 2018 with 22 years of experience
www.flowcontrolnetwork.com
in leading environmental, health and
safety excellence initiatives in both the
public and private sectors.
SPX FLOW presents plaque
to channel partner, Master
Pumps & Power
SPX Flow presented Master Pumps &
Power, a servicer of the SPX FLOW
Waukesha Cherry-Burrell positive dis-
placement pump range, with a recogni-
tion plaque that celebrated its 50 years
of service to North America. Bill Rice,
district sales manager for SPX, presented
the plaque to CEO and president Don
Moilen and Donnie Moilen, regional sales
manager of Master Pumps & Power.
Headquartered in Texas, Master Pumps
& Power has experience in industrial
pumping in the oil and gas and chemi-
cal industries.
Bureau Veritas names new VPs
Bureau Veritas, which provides testing,
inspection and certification TIC servic-
es, named TJ Johansen as senior vice
president and chief operating officer for
the oil and gas market segment. Based
in the Houston office, Johansen will be
responsible for leading the company’s
oil and gas commodities and indus-
tries group. With more than 20 years
of leadership experience, Johansen
joins Bureau Veritas from Kemira Oyj,
where he served as president of the
oil and mining division. Bureau Veritas
also named Maggie Laureano as vice
president and human resources head
for North America. She has more than
20 years of human resources leadership
experience across multiple industries.
Rockwell Automation hires
human resources VP
Rockwell Automation hired Karen
Keegans as senior vice president,
human resources, reporting to chairman
and CEO Blake Moret. Most recently,
Keegans was chief human resources
officer at Pentair and previously held
several senior leadership roles at Praxair
and Monsanto. She holds a bachelor’s
degree in economics from the University
of Western Ontario.
SL Mooney retires
from SEPCO
Sherrell “SL” Mooney retired from Sealing
Equipment Products Co. Inc. (SEPCO)
after 44 years of service to the indus-
try. Mooney has worked in nearly every
department at SEPCO, including most
of the areas within the plant and ulti-
mately in customer service. Patrick
Cunningham has completed his transi-
tion into Mooney’s role.
Market Updates
Growth in chemicals
industry is accelerating
the demand for
diaphragm pumps
A study from market intelligence firm
Fact.MR estimated global sales of dia-
phragm pumps to surpass 2 million units
by the end of 2018. Diaphragm pumps
will likely remain the preferred choice
among end users because of features
such as flexibility and isolation of the
fluid chamber. Increasing production of
aggressive chemicals is resulting in the
surging demand for air-operated double
diaphragm pumps, according to Fact.MR.
The overall outlook of the reciprocating
pumps market is anticipated to be posi-
tive, with demand for reciprocating pumps
expected to expand at a 5.6 percent com-
pound annual growth rate (CAGR) in terms
of value throughout the forecast period,
2018–2027.
Rotary pumps market expected
to surpass $4.4B in 2018
Fact.MR’s latest study on rotary pumps
market projects bullish growth for the
market. The study finds a significant rise
in adoption of rotary pumps in industrial
sectors such as oil and gas, water and
wastewater, mining and power generation.
Because of widening applications, the
rotary pumps market is likely to witness
3.3 percent growth in 2018, to exceed
$4.4 billion.
The rapidly changing pumps industry
will impel rotary pump manufacturers to
introduce more innovative and smarter
features of rotary pumps, according to
the firm.
February 2019 | 7
 The study finds that the sales of rotary
pumps with smaller capacities account
for around 40 percent revenue share in
the rotary pumps market in 2018.
Despite a variety of rotary pumps being
introduced by players in the rotary pumps
market, including gear, screw, lobe and
piston rotary pumps, the popularity of
rotary vane pumps is outpacing the other
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8 | February 2019
types. The study finds around 4 percent
year-over-year increase in the sale of rotary
vane pumps in 2018 over 2017, which is
the highest growth rate compared to all
the other types of rotary pumps.
According to the study, the rotary
pumps market is likely to grow at a healthy
CAGR of around 3.9 percent during the
forecast period of 2018 to 2028.
For more information:
Call: 1-800-Go-Festo
1-800-463-3786
www.festo.us/food
Oil & Gas
Oil and gas pump sales
at 9 million units in 2018
The oil and gas pumps market is likely
to witness sluggish growth, with global
demand surpassing 9 million units by
the end of 2018, according to a market
report by Fact.MR. Rising demand for
oil and gas is resulting in the growing
demand for equipment such as oil and
gas pumps.
End users of oil and gas pumps are
using centrifugal pumps on a large-
scale, owing to their low product and
maintenance costs as well as better
load and pressure-handling capa-
bilities. The demand for centrifugal
pumps is healthy in the upstream oil
and gas industry as the part of multi-
phase pumping application, according
to the report.
Analysts also expect the demand for
submersible pumps to grow in the near
future. Electric submersible pumps are
being used on a large scale as water and
oil separators.
Centrifugal pumps are also expected
to witness increasing demand for crude
oil transportation. Manufacturers in the
oil and gas pumps market are focusing
on pump modification to save a sig-
nificant amount of energy and improve
performance.
The study also predicts rapid growth
in demand for onshore oil and gas pumps,
with the market exceeding 4.8 million
units in 2018.
US crude oil production
up 2.2M barrels per day
from 2017
U.S. crude oil and other liquids produc-
tion increased in 2018, and the U.S.
Energy Information Administration (EIA)
forecasts it to average 17.8 million bar-
rels per day (b/d) for the year. That will
be the highest level since EIA records
began in 1994, and it will account for
an increase of 2.2 million b/d from the
2017 production level.
America surpassed Russia and Saudi
Arabia earlier in 2018 to become the
largest crude oil producer in the world
Flow Control
based on monthly data. U.S. crude
oil production was at record levels in
2018, and EIA forecasted that 2018
annual crude oil production would reach
10.9 million b/d, surpassing the previ-
ous annual high of 9.6 million b/d set
in 1970.
U.S. crude oil exports averaged 1.9
million b/d in 2018, about twice the
amount that was exported in 2017. Crude
oil overtook distillate as the largest U.S.
petroleum export.
The growth in U.S. exports of crude oil
and petroleum products led to a one-
week period in late November when the
at $86/b and $76/b, respectively. Prices
for each benchmark fell quickly after
that, and on Dec. 24, Brent reached an
annual low of $50/b and WTI reached
an annual low of $43/b.
Brent ended the year at $54/b, $13/b
lower than it began the year, and WTI
ended the year at $45/b, $15/b lower
than it began the year. This year marks
the first time since 2015 that crude oil
prices for these benchmarks ended the
year at a lower price than at the begin-
ning of the year. FC
Send news and events for consideration
to Molly Rogers at mrogers@
endeavorbusinessmedia.com.

GENUINELY
U.S. was a net exporter for the first time
in EIA’s data history.

Brent and WTI crude oil

end year at lower prices
than they began
RELIABLE.
Brent crude oil averaged $72 per barrel
(b) in 2018, and West Texas Intermediate Day in, day out performance. Year
(WTI) averaged $65/b in 2018, accord- after year. That’s what matters in a
ing to EIA. The prices for both crude oils pump. And that’s why we engineer
finished the year lower than they began. every Gorman-Rupp rotary gear pump
Brent and WTI each hit their highest
to be the most reliable, durable, and
prices during the year on Oct. 3, 2018,
easy-to-service pump on the market.

Upcoming events
Hydraulic Institute Conference
Feb. 24–28
St. Petersburg, Florida
pumps.org

ProFood Tech
March 26–28
Chicago
profoodtech.com

INTERPHEX
April 2–4
New York City
interphex.com

Offshore Technology Conference GRpumps.com

May 6–9
Houston
otcnet.org

Sensors Expo 551 © 2019 The Gorman-Rupp Company.

June 25–27
San Jose, California
sensorsexpo.com

www.flowcontrolnetwork.com February 2019 | 9

 Application Corner
By David W. Spitzer
Flowmeter slippage:
Avoiding the avoidable
E
very now and then, a portion of a
published article or internet post
catches my eye — sometimes
because it needs further explanation.
A recent article referring primarily to
positive displacement flowmeters stated,
under the leakage heading, that fluid
leaking past the moving parts “rather
than turning them … can occur when
a meter starts from a zero-flow condi-
tion. To avoid slippage at low flow rates,
installers may have to increase flow rate
at startup, then back it off once the right
momentum is achieved.”
Notwithstanding that leakage and slip-
page are different but appear to be used
synonymously, installers may have little
interest in whether the flowmeter oper-
ates because they are typically long gone
before operation begins. In addition, hav-
ing to increase the flow rate every time
flow is started is an excellent reason to
consider another flowmeter or flowmeter
technology.
Some years ago, I noticed that a par-
ticular flow control valve was manually
opened for about 30 seconds every day
to remove accumulated solids. This was
not acceptable because we wanted the
operators to focus on the operation, not
on minutiae and busy work. Within a few
weeks, a different style valve was installed
that did not plug.
In this case, installation of a flowmeter
that requires more than normal attention
10 | February 2019
is not advised unless it is the only flow- Having to increase
meter that will work in the application.
In addition, operators do not necessar-
the flow rate
ily have the luxury of increasing the flow every time flow
during startup because the additional
is started is an
amount of the material may create a
hazard in some operations and/or waste excellent reason
a valuable raw material or product. In to consider
some plants, no suitable location may
exist to store the additional material. another flowmeter
It is bad enough to inherit a problem or flowmeter
installation such as the above flow con-
trol valve, but efforts should be made
technology.
to not install new inconveniences that
you or your successors will need to
address. FC
David W. Spitzer is a regular contributor
to Flow Control and a principal in Spitzer
and Boyes LLC, which offers engineer-
ing, seminars, strategic marketing con-
sulting, distribution consulting and expert
witness services for manufacturing and
automation companies. Spitzer and
Boyes is also the publisher of the
Industrial Automation INSIDER. He has
more than 40 years of experience and
has written more than 10 books and
400 articles about flow measurement,
instrumentation and process control.
Spitzer may be reached at 845-623-
1830 or via spitzerandboyes.com. Click
on the Products tab to find his Consumer
Guides to various flow and level mea-
surement technologies.
Flow Control
 Which of the following flowmeters could be used to measure 10
Quiz Corner to 100 gallons per minute (gpm) of liquid with a specific gravity
of 1.20 and a viscosity of 500 centipoise (cP) in a 3-inch pipe?

A. Coriolis mass B. Differential pressure C. Magnetic D. Positive displacement E. Thermal F. Turbine G. Vortex shedding

T
hermal flowmeters are not applicable because they D) flowmeters remain as potential technologies to apply
are used in gas service (Answer E). Reynolds num- in this application.
ber at maximum flow can be calculated as 3160
x 100 x 1.2 / 500 x 3, or approximately 250. Operation Additional complicating factors
in the laminar flow regime with Reynolds numbers of 25 Many liquids with high viscosities, such as hydrocarbons,
4kodiak/iStock

to 250 generally precludes the use of differential pres- are not conductive, so magnetic flowmeters (Answer C)
sure (Answer B), turbine (Answer F) and vortex shedding can sometimes be eliminated from consideration, simpli-
(Answer G) flowmeter technologies. Coriolis mass (Answer fying the selection process. FC
A), magnetic (Answer C) and positive displacement (Answer

www.flowcontrolnetwork.com February 2019 | 11

Cover Story: Food & Beverage
Heating solutions for
food processing
Thermal efficiencies can be maximized when the
type of process and fluid viscosities are considered.
By Matt Hale, HRS Heat Exchangers
F
or food and beverage manufac-
turing — as varied as dairy,
fruit and vegetable processing,
meat, prepared foods, brewing and
dietary supplements — the demand
for heating (and cooling) requires
a large amount of energy. The U.S.
Department of Agriculture (USDA)
Economic Research Service 1 esti-
mated that food processing in the U.S.
accounted for some 2.75 quadrillion
Btu (806 TWh) of energy in 2002, an
increase in energy use by this sector
of 8 percent per year since 1997.
While there are many energy uses in
food processing, this figure includes
ovens, boilers and space heating,
12 | February 2019
as well as processes such as drying,
sterilization and concentration.
Minimizing environmental
impact and lowering costs
In order to reduce environmental impact
and make best use of byproducts and
biomass wastes, many food producers
in recent years have invested heavily
in bioenergy production projects such
as anaerobic digestion and biomass
combustion, as well as other forms of
renewable energy. While this has helped
to reduce the sector’s environmental
footprint, maximizing process efficiency
and thermal efficiencies, in particular,
is sometimes overlooked, not only as a
(Above) The pasteurization process can
change the properties of viscous foods.
All images courtesy of HRS Heat Exchangers
way of improving environmental perfor-
mance, but also as a means to generate
greater economic returns.
Recapturing and reusing heat from
other sources, such as surplus heat from
cooling operations or spare boiler capac-
ity, can be an effective way of increasing
capacity or adding a new production pro-
cess without the need for new, major heat-
ing or energy infrastructure. Depending
on the application, some heat exchanger
equipment has been shown to recover as
much as 50 percent of previously wasted
Flow Control

heat, which can then be used for water,
space or process heating, waste treatment
or other thermal applications.
Factors to consider
While some processes and materials
require specific equipment, such as
ovens or retorts, heat exchangers are an
effective and efficient solution and are
more likely to enable heat regeneration
than other systems. The choice of heat
exchanger depends on many factors,
such as the nature of the process to be
www.flowcontrolnetwork.com
Newtonian and non-Newtonian fluids will
behave differently under different temperature
and pressure regimes.
carried out (pasteurization, sterilization
or dehydration), the viscosity of the food
or drink being processed and whether it
contains particles or pieces.
Furthermore, Newtonian and non-
Newtonian fluids will behave differently
under different temperature and pres-
sure regimes, and this will affect the
handling required during processing.
For example, if subjected to too much
pressure, certain sauces may shear,
resulting in failure to meet the end
specification, such as pizza sauce not
(Left) The HRS Unicus is ideal for difficult
heat transfer applications with viscous fluids
or with a high risk of fouling.
staying on the pizza. Another chal-
lenge is presented by certain fat-free
products, which become more or less
viscous with temperature, so there may
be more fluid on the cooling side of the
heat exchanger than the heating side.
Benefits of corrugation
Such issues can be overcome by specify-
ing the correct type of heat exchanger for
the task in hand and by careful system
design. Corrugated tube heat exchangers
are available in various configurations,
so delicate materials such as cream can
be processed without damage. The cor-
rugated design also minimizes fouling in
the heat exchanger, which increases the
thermal efficiency and prolongs opera-
tional periods between cleaning. In addi-
tion, corrugated tube heat exchangers
have a lower pumping requirement than
smooth tubular heat exchangers due to
their compact nature, which results in a
lower pressure drop. This helps increase
operational life while reducing mainte-
nance costs compared with other types
of heat exchangers.
Reducing waste
For some materials, such as curd produc-
tion in the dairy sector, increased tur-
bulence can be beneficial. Alternatively,
February 2019 | 13
 Corrugated tube heat exchangers are available in
various configurations, so delicate materials such as
cream can be processed without damage.

where low pressures are required, scraped

surface heat exchangers keep things flow-
ing smoothly while handling the product
gently — this is one way to overcome
the aforementioned pizza sauce example.
Using the right type of heat exchanger can
also help reduce product losses caused
by materials remaining in equipment at
batch changeovers or when cleaning is
required. Some scraped surface heat
exchangers can be configured to run in
reverse, effectively removing product from
the heat exchanger without damaging it or
affecting its quality.
When dealing with any food process-
ing machinery, it is critical to check for
compliance with the necessary legisla-
tion; however, ultimately, the selected
equipment must perform as required.
And, as with any capital expenditure,
it is important to compare not just the
initial capital costs, but also the opera-
tional and maintenance costs across
the life of the machinery. All heat
exchangers are not alike, but these
differences mean that there is a heat
exchanger solution that fits different
food processing needs. FC

Resources
1. USDA (2010): Energy Use in the U.S.
Food System. http://web.mit.edu/
dusp/dusp_extension_unsec/reports/
polenske_ag_energy.pdf.

Matt Hale is the interna-

tional sales and market-
ing director for the HRS
Group. He is responsible
for overseeing and developing the compa-
ny’s strategies for business development
and marketing. Hale has a background
of more than 20 years within process
and mechanical engineering and aims to
provide effective heat transfer solutions
to overcome industry challenges. With
a focus on renewable energy, he works
The HRS R Series can run in reverse at the end of a batch to reclaim valuable products, closely with the global sales teams to
effectively emptying the heat exchanger without damaging or affecting quality. achieve their goals.

14 | February 2019 Flow Control

Features: Storage Tank Safety
A systemic approach to
overfill protection
Today’s technologies can point out weak links when monitoring
the condition of liquid storage tank safety systems.
By AnnCharlott Enberg and Lydia Miller, Emerson Automation Solutions
F
or process plants, terminals and
tank farms designed to receive and
send out millions of gallons of flam-
mable hydrocarbons, the ability to safely
handle such movements should be a fact
of life. The same is true for smaller com-
panies that maintain tens-of-thousands of
gallons of products or feedstocks. Even if
their products are benign, a large enough
spill of practically anything can create an
environmental incident.
This is precisely why tanks that are
routinely filled and emptied during nor-
mal operation need to have a mech-
anism to avoid overfilling incidents.
The concept is basic: It is impossible
to put 50,000 gallons of liquid into a
40,000-gallon tank. Yet such attempts
happen, usually because operators do
not realize the condition of the con-
tents of the existing tank. Insurance
data shows that for all the tanks around
the world, there is one overfilling inci-
dent for every 3,300 filling operation.
Perhaps that sounds like a small pro-
portion, but overfill accidents can be
devastating. Consider the following two
well-documented examples.
In Hemel Hempstead, England,
December 2005, the Buncefield oil
storage depot was the site of the largest
explosion in that country since World War
II. Operators filling a tank with gasoline
were unaware of its full condition, and
250,000 liters flowed out of vents onto
the ground. Truck drivers approaching
the facility called the control room and
warned of the situation, but it was too
late; the fuel found an ignition source.
There was no functioning level instrument
on the tank nor was there a functioning
overfill protection system.
www.flowcontrolnetwork.com
In Bayamón, Puerto Rico, October Operator awareness
2009, the Caribbean Petroleum (CAPECO) Operators must have an accurate, com-
terminal was transferring more than 10 plete and real-time picture of the contents
million gallons of unleaded gasoline from of every tank. One common recipe for an
a tanker ship to storage tanks. Operators overfill incident is when operators begin
were trying to spread the large load among pumping liquid into a tank without real-
multiple tanks, but one of the tanks had izing it is closer to being full than they
a malfunctioning mechanical level gauge. thought. It should be easy to see the
Once filled, gasoline flowed out of the vents, contents of any tank from the control
leaked through the dikes and ignited when
it reached electrical equipment. Within
seconds, the explosion caused a blaze
that destroyed 17 of the facility’s 48 tanks.
There are other examples, but the point
should be clear: An overfill can have dev-
astating consequences, and an overfill
prevention system depends on the right
combination of level measurement instru-
ments, operator interfaces, safety con-
trols systems and final control elements.
Additionally, condition monitoring of those
components helps ensure an operational
safety system. This article looks at how
these elements can and should interact.
Figure 1. Rosemount Radar Level
Transmitter available in an SIL
3-certified version
All images courtesy
of Emerson Automation
Solutions
February 2019 | 15

Figure 2. This diagram of a comprehensive tank management system illustrates the overfill
protection system on the left. All the critical elements of the safety-instrumented function
are included: sensor, logic solver and final control elements.
room, but this depends on having accu-
rate and reliable level instruments for
every situation. In both the Buncefield
and CAPECO incidents, level instruments
were malfunctioning.
Safe and reliable proof-testing
Proof-testing is necessary to make sure
the safety system will work when it is
required. Unlike a basic process control
system, an overfill prevention system
does not operate on a regular basis. It
only needs to operate when tank level
reaches an extreme point. But to assure it
is operational when needed, proof-testing
is required on a regular basis, and partial
proof-testing can extend the time period
before a full proof test is required.
Traditional proof-testing methods involve
multiple technicians in the field working with
someone stationed in the control room
to verify the system’s response. The field
technicians must climb tanks to access
instruments and attempt to cause them
to trip, exposing them to hazardous con-
tents and increased safety risks. Performing
16 | February 2019
proof tests this way is error-prone and time-
consuming. It can also interfere with pro-
duction, causing negative financial impact.
Partial proof-testing of level instru-
ments can now be accomplished easily
from the control room with devices that
have been designed especially for use
in safety-instrumented systems (SISs).
Devices that provide a high safe failure
fraction can also help achieve a higher
level of safety.
Additional condition monitoring aids,
such as a digital valve controller for SIS
applications, have the potential to do par-
tial stroke testing of the valves as well as
monitoring the health of valve assemblies.
Automatic shutoff
The system controlling filling operations
must also have effective alarms com-
bined with automated shutoff. When
using a manual filling procedure, opera-
tors must be made aware when a high-
level threshold has been crossed while
there is still plenty of time to take correc-
tive action before an automated shutoff
Figure 3. Rosemount Vibrating
Fork Level Detector available
in an SIL 2-certified version
system intervenes, which will
likely cause some disruptions.
Naturally, this approach depends
on having effective instrumentation.
A risk assessment should be per-
formed for every tank to determine the
level of safety required. Automated filling
control systems must be equipped with a
safety system capable of stopping the filling
operation before the tank begins to overflow
(see Figure 2). Such an SIS involves three
functional components: a level instrument,
a logic solver and final control elements.
The actual design of an SIS is complex,
and there are experts to consult for help,
but to understand the basic concepts, the
following describes each element individu-
ally and explores valuable advances.
The level instrument (like the one
shown in Figure 1) can use a variety of
technologies to provide a continuous or
point level measurement. It must be able
to function independently of any other
instrument on the tank, and it must
have this safety function as its primary
duty. Vibrating forks (as shown in Figure
3) are commonly used in this applica-
tion because they are simple and highly
reliable. Recent advances in diagnostics
allow for condition monitoring of level
instruments while they are online, which
allows easier partial proof-testing.
The logic solver is a complex data
reader and performer. Its job is to read
the signal from the instrument and
perform a specified function when the
sensed value crosses the threshold.
Like the instrument, it must be a certi-
fied safety device, and it must be able
to perform its function independently
without depending on any other part of
a larger automation system. It may send
data to the larger process automation
system, but its real-time control function
must be entirely self-contained.
What action the logic solver takes is
determined by the nature of the equip-
ment. Typically, it will shut down any
pumps moving liquid into the tank and will
close strategic valves to contain the flow.
The logic solver may respond immediately
Flow Control
 upon receiving the signal from
the level instrument, or it may
have a delay built in to allow for
a brief transient.
Turning off a pump is easy
enough, but closing valves can be
more complex; this is where the final
control elements come in. Again,
these must be capable of function-
ing independently in any situation. If
the system is completely automated, the
relevant valves should be outfitted with
actuators designed for SIS service. Some
locations still depend on manual valve
closing to complete an emergency shut-
down action. Besides the main drawback
of requiring personnel to go into the field in
a potentially dangerous situation, a manual
system also depends on a person’s abil-
ity to locate and close the correct valves
quickly enough to forestall a release.
Following design
requirements
These systems must be designed appro-
priately, observing all relevant safety
standards and best practices, such as
IEC 61511, API 2350 and potentially
others. Newer technologies are also
replacing many legacy mechanical level
instruments.
When choosing level instruments to
replace these devices, selecting a third-
party SIL-certified device will provide many
additional benefits besides measurement
reliability. They can make safety loop cal-
culations much simpler and more reliable.
While it is helpful and even perhaps
required to use safety-certified instru-
ments and supporting devices, these
alone do not ensure an effective SIS.
They must be applied and integrated cor-
rectly. Once installed, the systems must
be tested and verified, and all appropri-
ate procedures should be followed on
a regular basis. Choosing devices that
provide easier proof-testing will ultimately
reduce the life cycle costs of an overfill
prevention system.
Layers of protection
All of these systems are designed to serve
as layers of protection for the plant (see
Figure 4), people and surroundings, while
www.flowcontrolnetwork.com
avoiding product loss, by providing the
following functionality:
• When operators can see an accurate
picture of what is in each tank and
monitor filling operations, they can
control the outcome correctly and
avoid problems.
• Should operators lose track of what
is happening, an overfill prevention
system can help ensure the opera-
tion can be brought under control
before an incident escalates.
• Even if operators do not respond or
there is a failure of the process
automation system, an automated
overfill prevention SIS can perform
an emergency shutdown without the
need for any human intervention.
These three types of actions all avoid
a release of liquid. In the event of every-
thing failing, mitigation layers take over
in the form of dikes and emergency
response services. Naturally, these are
drastic situations and well beyond what
anyone wants to see happen.
Putting it all together
When dealing with tanks operating in pro-
cess industries or those that store products
at a tank farm or terminal, one of the major
hazards to avoid is overfilling the tanks.
This is especially important with chemicals
that may explode, catch on fire or affect
the health of people or the environment.
Effective tank management involves
safety but should encompass far more.
It begins with accurate and reliable level
measurement instruments using the best
Figure 4. Prevention and mitigation
layers of protection are designed to
prevent catastrophic incidents.
technology for the application. Data must
be collected, processed and displayed
appropriately to provide a high degree
of operator awareness. In both the
Buncefield and CAPECO incidents, the
mechanical level instruments had failed
and the operators did not know it.
An effective system integrated with
sophisticated instruments avoids many
of the failure modes common to older
technologies and can even perform self-
diagnostic routines to verify every element
is functioning correctly. In the event of an
instrument failure, an alarm is activated
to make operators aware of the issue.
Third-party certified devices make
safety loop calculations simpler, because
part of the work has already been done by
the supplier. Devices designed especially
for SIS applications will offer even more
advantages due to specific features, such
as online partial proof-testing, designed to
reduce safety life cycle costs. It is impor-
tant to take the time to select devices
designed specifically for use in an overfill
prevention system. FC
A n n C ha r l ot t E nb e r g i s
a functional safety manager
with Rosemount Level,
Emerson Automation Solutions.
Lydia Miller is a senior
marketing engineer with
Rosemount Level, Emerson
Automation Solutions.
February 2019 | 17
Features: Compressors
Prediction of centrifugal compressor
performance in off-design condition
This general method and calculation tool can be used
to evaluate compressor performance.
By Massimiliano Di Febo and Pasquale Paganini, IPC
C
entrifugal compressors are a vital
component within process plants.
Compression machines are widely
used in upstream as well as middle-
stream plants, accomplishing critical mis-
sions for overall production goals in most
cases. In these plants, compressors are
often one of the most important assets
due to their impact on capital invest-
ment as well as output loss caused by
possible machine downtime and related
maintenance and repair costs.
Understanding if the machine is running
and working properly assumes a primary
role. The capability to detect early indica-
tors of eventual malfunctioning and timely
identifying causes and possible remedies
contribute to plant proficiency and mini-
mize overall operational costs.
This direction is generally known as
predictive maintenance. Today, a pre-
dictive approach is present across most
industries and applied over several kinds of
machinery. For the most common centrifu-
gal machines, predictive techniques com-
monly implemented are connected to the
vibrational and structural dynamic aspects
of the machine rotor operational condi-
tions. This phenomenological approach
can be applied in the design stage where
insight is given by OEMs to rotor dynam-
ics, but often, it assumes a more practical
and empirical form on the operation floor
where machine vibrational parameters are
measured and compared to acceptable
limits and used merely for alarm triggering.
Predictive strategies based on the
analysis of performance are increasing
their presence as tools for diagnostic
and evaluation of machine health status
during operational time. For centrifugal
18 | February 2019
pumps, for instance, the use of a machine
model for the purpose of comparison of
measured performance to design ones is
relatively straightforward. For centrifugal
compressors, the same process is more
complex because of the dependency of
compressor performance from the gas
mix composition and operative inlet condi-
tions (inlet pressure and inlet temperature).
Therefore, for centrifugal compressors,
an approach based on performance
assessment requires a more complex
machine model that should embed and
couple several calculation capabilities
from aeromechanics to thermodynamic.
One of the main difficulties for the
analysis of centrifugal compressors’
operative performances arises from the
need to have the available compressor
performance map adjusted to actual inlet
conditions. Usually, expected performances
are described in terms of graphs of dis-
charge pressures, discharge tempera-
tures, polytropic heads, efficiencies and
absorbed power, related to the design
inlet gas conditions. In general, it may
happen that inlet conditions in the field
are different from specification conditions
defined in the machine’s data sheets. A
somewhat diffused practice consists in
trying to reduce the complexity of the
problem, considering the compressor
head as invariant with inlet gas conditions
and applying simplified machine formulas.
While this method holds for very low pres-
sure ranges and constant gas mixes, it
introduces considerable errors as soon as
the pressure increases and the gas mix
variability is introduced into the problem.
In this situation, in order to assess
compressor performance, it is necessary
to adjust the design performance to
operative conditions, taking into account
the complexity of the problem and then
compare that to measured values. This is
basically the approach indicated on the
ASME PTC10 (Performance Test Code on
Compressors and Exhausters) standard.
This paper presents a general method
and calculation tool for prediction of cen-
trifugal compressor field performances
in off-design condition. All numerical
evaluations executed with Cmap software
reported here have been developed using
most-recent thermodynamic theories
and machine aeromechanical models in
accordance with PTC10.
Method
The following section provides a simple
explanation of the calculation process
used to evaluate the compressor perfor-
mances. As a starting point, we consider
that, for a centrifugal compressor, perfor-
mances are strictly linked to the inlet gas
conditions. This consideration is valid both
to the design and off-design performance.
Begin with the availability of a centrifu-
gal compressor performance curve, the
relevant gas mix composition and ther-
modynamic conditions (pressure and
temperature). Having this input data avail-
able, the software will perform all complex
calculations — fully automated — and
will produce the expected compressor
performances for inlet pressures, inlet
temperatures and gas mix compositions
different for design/reference ones.
Calculation algorithms used are able
to predict both machine behavior and
thermodynamic real gas properties in off-
design conditions. The list of gases that
Flow Control
Item Gas name Symbol
1 Acetylene C2H2
2 Ammonia NH3
3 Argon Ar
4 Benzene C 6 H6
5 Iso-Butane C4H10
6 n-Butane C4H10
7 Iso-Butylene C 4H 8
8 Carbon Dioxide CO2
9 Carbon Monoxide CO
10 Chlorine Cl2
11 n-Decane C10H22
12 Ethane C2H6
13 Ethyl Alcohol C2H5OH
14 Ethylene C2H4
15 Helium He
16 n-Heptane C7H16
17 n-Hexane C6H14
18 Hydrogen H2
19 Hydrogen Chloride HCL
20 Hydrogen Sulfide H2S Figure 1. How Cmap works

21 Methane CH4
22 Methyl Alcohol CH3OH can be configured are shown in Table 1. method, although “as tested” maps
From a fluid dynamic point-of-view, a may be preferable.
23 Nitrogen N2
strict similarity of flow at each perfor- b. Reference input conditions: Reference/
24 n-Nonane C9H20 mance point is necessary. For this reason, design maps are linked to specific
25 Iso-Pentane C5H12 the nondimensional parameters head inlet conditions such as inlet pres-
26 n-Pentane C5H12
coefficient, flow coefficient and Mach sure, inlet temperature and gas mix
number must be conserved primarily. composition. This set of data shall
27 n-Octane C8H18
The proposed method needs the be stated in order to proceed to off-
28 Oxygen O2 following inputs: design calculations.
29 Propane C 3H 8 a. Reference/design compressor maps: c. Off-design input conditions: These are
30 Propylene C 3H6
In general, these maps provided by the conditions at the compressor inlet
the machine’s OEM give a reliable (pressure, temperature and gas mix
31 Sulphur Dioxide SO2
indication of the machine capability composition) in which the new per-
32 Water Vapor H20 and are considered here as a starting formance should be obtained. Off-
33 1-Butene C 4H 8 point. In this case, input data should design conditions may be alternative
be affected by error, and these inlet conditions to be considered in the
34 2-Butene C 4H 8
errors should be propagated in the compressor design stage or may be
35 1.3 Butadiene C 4H 6 outputs generated by this method. the actual inlet condition in a specific
36 Ethyl Chloride C2H5Cl OEMs usually supply two different time during compressor operation.
37 Methyl Chloride CH3Cl machine maps related to different
moments of the compressor manu- Starting from these described inputs, the
38 Pentylene C5H10
facturing process. “Expected” maps method proceeds to calculate the com-
39 Propadiene (Allene) C3H4 are usually issued in the commercial/ pressor performances in off-design inlet
40 Methyl Acetylene (Propyne) C3H4 design stage, as tested maps are conditions. Performance obtained as output
41 Toluene C7H8 issued at the end of the manufactur- from the described method should be ref-
ing process when the compressor is erenced here as off-design conditions, i.e.,
42 Freon R134a CH2FCF3
shop- or field-tested. In general, both design performance adjusted to off-design
Table 1. Gas components maps may be used as input for the operative conditions. When reference is

www.flowcontrolnetwork.com February 2019 | 19

 Pressure: 40.2 bar a

Temperature: 50°C

Gas Mixture (Mw 19.24 g/mole):

Methane 80.51%

Nitrogen 1.46%

Ethane 14.69%

Propane 3.19%

I-butane 0.07%

N-butane 0.08%

Figure 2. Design map compressor 1: discharge pressure versus inlet flow. Table 2. Inlet design gas condition compressor 1

Pressure: 150 bar a

Temperature: 37°C

Gas Mixture (Mw 19.1 g/mole):

Methane 87%
Nitrogen 1.2%
Ethane 3.5%
Propane 0.8%
I-butane 0.5%
N-butane 0.5%
Carbon Dioxide 4.5%
I-pentane 0.1%
N-pentane 0.1%
N-octane 0.1%
Hydrogen Sulfide 1.7%

Figure 3. Design map compressor 2: discharge pressure versus inlet flow. Table 3. Inlet design gas condition compressor 2

Pressure: 43 bar a

Temperature: 47°C

Gas Mixture (Mw 19.64 g/mole):

Methane 78%

Nitrogen 0.5%

Ethane 17.9%

Propane 3.5%

I-butane 0.03%

N-butane 0.07%

Figure 4. Comparison of discharge pressure between design and off-design condition (compressor 1). Table 4. Inlet off-design condition compressor 1

made to off-design performance in
off-design operative condition during
operational time, these performances
should be indicated also as “actual”
performance. Calculation of off-design
performance requires the capability to
extract the invariant information that
describes the compressor behavior and
use this information to rebuild the perfor-
mance in new conditions. These calculations
are intimately coupled with thermodynamic
of gas compression and thermodynamic
of real gas mixtures, so a variation in
each component of the gas mixture is
potentially able to manifest its effects,
as well as a change of the inlet pressure
and temperature. The connection among
these different modeling areas allows
the method to provide an accurate pre-
diction of the compressor performance.
The method does not require information

20 | February 2019 Flow Control

 Pressure: 154 bar a

Temperature: 30°C

Gas Mixture (Mw 20.1 g/mole):

Methane 83.7%
Nitrogen 1.1%
Ethane 4.7%
Propane 2.8%
I-butane 0.4%
N-butane 0.4%
Carbon Dioxide 4.0%
I-pentane 0.5%
N-pentane 0.2%
N-octane 0.3%
Hydrogen Sulfide 1.9%

Figure 5. Comparison of discharge pressure between design and off-design condition (compressor 2). Table 5. Inlet off-design gas condition compressor 2

about the internal parts of the machine, With reference to field values, Tables status and should give the analyst an
and it should not be considered a design 6 and 7 compare the pressures and tem- understanding of possible causes that
tool, but more correctly, as an analysis tool peratures as read from transducers to the may justify the observed difference.
that starts its job after the completion of value predicted by the Cmap software. The analysis developed using Cmap
the machine design stage. The same comparison has been exe- also obtained an evaluation of the effi-
cuted for head and polytropic efficiency. ciency deviation (difference between
Case study: Prediction In these tables, note that for compres- the actual compressor efficiency and
of performance in sor 1, the maximum error calculated is the expected efficiency in the actual
off-design conditions less than 1 percent, and for compressor operative conditions). Time trends of
The following describes how the presented 2, the error calculated is about 9 percent. calculation results provided a useful
method is applied using the Cmap soft- The analysis indicates that compressor analytical basis for compressor main-
ware tool through two real cases. The com- 1 was running with operative performance tenance decisions. The method has been
pressors under study were running under aligned with design expectations; how- profitably used to predict compressor
off-design inlet conditions. The analysis ever, compressor 2 was running with performances and support planning of
developed with Cmap obtained the perfor- performance not aligned with design machinery maintenance activities.
mances in these off-design conditions and expectations. This comparison gives the Cmap performs the compressor per-
a comparison to measured field values. In compressor analyst an important quan- formance prediction using different equa-
these case studies, the compressor per- titative indication on the machine health tions of state (EOS) depending on gas
formances map in design condition were
available for both machines.
Figures 2 and 3 show the design maps
(discharge pressure versus inlet flow) for
compressor 1 and compressor 2 and rela-
tive design inlet conditions.
Table 2 indicates the inlet design gas
conditions of compressor 1. Table 3 indi-
cates the inlet design gas conditions of
compressor 2.
Starting from these maps, the expected
performance curves in the off-design con-
ditions have been calculated. Tables 4
and 5 indicate the off-design inlet condi-
tion for compressor 1 and compressor 2.
Figures 4 and 5 compare the perfor-
Figure 6. Screenshot of Cmap 2.0
mance curves (discharge pressure versus
inlet flow) in design and off-design condition. Properties Field value Cmap predict value Percentage error
The Cmap software was able to calculate,
at the actual flow, the values of expected Discharge pressure [bar a] 98 97.6 + 0.4
pressure, temperature, head and efficiency Discharge temperature [°C] 122 123 - 0.8
in the actual (off-design) conditions and
then compare to the measured ones. Table 6. Compressor 1 predicted values

www.flowcontrolnetwork.com February 2019 | 21

 Properties Field value Cmap predict value Percentage error

Discharge pressure [bar a] 240.5 263.7 - 8.8

Discharge temperature [°C] 99 102 - 2.9 Table 7. Compressor 2

predicted values

mix considered in the calculation. For
hydrocarbon gas mixture, Lee-Kesler or
PR EOS can be used. For Freon R134a,
the MBWR EOS should be selected to
determine the thermodynamic properties
of the operating fluid.
Conclusion
Experiences with real machinery showed
that the compressors’ performance predic-
tion obtained with Cmap software are in
very good alignment with OEM predictions
and field measurement for machines in
good condition. Also, experience showed
that, in most cases, the deviation of a
parameter, such as efficiency, indicates an
incoming problem on the machine.
The proposed method may be used fully
automated and could provide benefits for
machines that work in high pressure ranges
and under time-varying process conditions.
An automated application of Cmap may
be able to provide continuous monitor-
ing of machine performance and auto-
mated surveillance and diagnostics. Also,
compressor protection from surge can be
automatically and continuously updated
to actual inlet conditions, overcoming
limitations of actual systems.
Methods proposed and described in
this paper can help to:
• Predict the performances of a cen-
trifugal compressor in off-design
condition. The prediction of com-
pressor performances is accurate
even at high pressures, where the
ideal gas theory commonly used
introduces considerable errors.
• Predict the modification of surge
points in actual operative conditions,
with different inlet pressures and tem-
peratures and different operative gas,
and to implement advanced protec-
tion from surge.
• Obtain useful indications on the health
of the compressor (diagnostics) based
on the capability to analyze the perfor-
mances and efficiency of the machine
in a simple and immediate way.
• Support decisions and planning of pre-
dictive maintenance and activities. FC
Massimiliano Di Febo is operation man-
ager at IPC. He can be reached at
massimiliano.difebo@ipc-eng.com.
Pasquale Paganini is a technical man-
ager at IPC. He can be reached at
pasquale.paganini@ipc-eng.com. For
more information, visit ipc-eng.com or
compressormap.com.

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22 | February 2019 Flow Control

Features: Sensors
Using 3D metal printing for
flow and pressure sensors
Quality standards will be required for the adoption
of additive manufacturing of flow and pressure meters
using related corrosion-resistant alloys.
By Doug Sparks, M2N Technologies
3
D printing is becoming ubiquitous
and is poised to affect flow control
products. 3D printing, or additive
manufacturing (AM), traces its roots back
to 2D inkjet printing in the 1970s. Polymer
3D printing began in the late 1980s, with
metal 3D printing coming into play in the
late 1990s. By 2006, both aluminum and
titanium could be printed with stainless
steel, cobalt and nickel alloys, as well as
tungsten coming online a few years later.1
Various types of 3D metal printing are
available and include selective laser melt-
ing (SLM) or direct metal laser sintering
(DMLS), which uses metal powder as a
starting material. Essentially, a laser selec-
tively melts a 2D design onto a flattened
bed of powder before a new powder layer is
pushed on top and the process is repeated.
Directed energy deposition (DED) or laser
metal deposition (LMD) is a powder-fed
system that sends a highly concentrated
metal powder stream through an extruder,
which is immediately met with a laser at
the surface of the part. DED is a highly
accurate metal 3D printing process, which
can also be used to repair broken parts.
Electron-beam melting (EBM) is also used
for 3D printing in which the raw material can
be either metal powder, filaments, rod or
www.flowcontrolnetwork.com
wire. These printing methods can be done
under vacuum to reduce porosity, oxidation
and other defects. Emerging metal printing
methods include the use of controlled elec-
troplating and the printing of metal powder
in a liquid polymer suspension.
Industrial applications
3D metal printing has several advantages
over traditional machining. Material scrap
is lower since it is a direct print additive
process versus a subtractive machining
or etching process. By printing a single
piece instead of using assembly steps,
the manufacturing process can be sim-
plified. Metal and plastic 3D printing is
ideal for fast prototyping and low-volume,
high-cost products or for the replace-
ment of legacy products. Features such
as weight-reducing internal lattices can
also be formed using AM techniques.
The aerospace industry has trailblazed
the tooling, materials, metrology and
quality standards for 3D-printed metal
that can be leveraged by the chemical
processing and automotive industries.
Many of the additive manufacturing alloys
developed for aerospace applications are
corrosion-resistant and are already in use
in the chemical processing markets.
Marina_Skoropadskay/iStock
Post-processing
Metal additive manufacturing does not
stop after the 3D printing step. For appli-
cations demanding reliability and high
quality, post-processing will be required.
Post-processing of printed metal parts
can start immediately after the printing
step. For laser and e-beam fabrication
metal, the product is in a state similar to
a welded metal part. Significant stress
is found in the metal structure. As in the
case of welding, an anneal step can reduce
some of this built-in stress, which reduces
the likelihood of warpage and cracking. The
anneal, often in an inert atmosphere or
vacuum, can be done before or after the
part is removed from the build plate. Hot
isostatic pressure is also used in some
aerospace parts to improve fatigue life of
the AM metal parts. A band saw or elec-
trical discharge machining (EDM) can be
used to remove the part from the build
plate. Trapped metal powder may need
to be shaken out of cavities.
Next, the relatively, as-printed matte
surface finish can be improved with
machining, bead blasting or tumbling.
Machining and surface treatments are
also common to ensure dimensional
specification and smooth outer surfaces.
February 2019 | 23
 ISO 17296-3:2014
Topic
Standard
ISO / ASTM52915 - 13 Design
Materials &
F2924 - 14
Processes
Materials &
F3001 - 14
Processes
Materials &
F3055 - 14a
Processes
Table 1. ISO 17296-3:2014 Standard examples for metal additive manufacturing
After the preceding machining and anneal
steps, a cleaning step is used to remove
any powder or residue.
Finally, like conventional cast and
machined parts, metrology is important
to ensure quality. Metrology is required
to make sure the part meets the speci-
fications and is free of voids and cracks.
Quality tests for aerospace and medical
devices are preferably nondestructive
and can include dye-penetrating tests,
ultrasonic scanning, X-ray and computed
tomography (CT) scanning. For some
applications, witness coupons, powder
chemistry and microstructure analysis are
required. Internal cavities, channels and
lattice structures can be a complicating
factor in final inspection.
Additive manufacturing
versus casting
What differentiates AM from machining
and casting of metals? One benefit of
3D printing, like investment casting, is
a.
Figure 1. (a) 3D-printed stainless steel pressure sensor; (b) thin film Wheatstone bridge
on a polished stainless steel surface. Figures courtesy of M2N Technologies
24 | February 2019
Description
Standard Specification for Additive
Manufacturing File Format
Standard Specification for Additive
Manufacturing Titanium-6 Aluminum-4
Vanadium with Powder Bed Fusion
Standard Guide for Characterizing
Properties of Metal Powders Used for
Additive Manufacturing Processes
Standard Specification for Additive
Manufacturing Nickel Alloy (UNS
N07718) with Powder Bed Fusion
the ability to combine multiple product
elements together into a single piece with
minimal wasted materials. 3D printing is
ideal for complex parts, low-volume appli-
cations and where shorter lead times are
required. New methods of printing metal are
also adding minimum feature size as well
as internal lattices and offer advantages
for additive manufacturing over other form-
ing methods like casting and machining.
3D printing standards
for quality
To enter mainstream chemical processing
applications, AM products and processes
need to pass the same quality certifica-
tion processes that other metal-forming
methods have in the past. The aerospace
industry has pushed this technology into
compliance with existing standards and
is creating new AM-specific standards.
Both the International Organization for
Standardization (ISO) and ASTM have
generated metal 3D printing standards.
b.
Additive manufacture is defined by ASTM:
F2792 - 12a (2012) as the “process of
joining materials to make objects from
3D model data, usually layer upon layer,
as opposed to subtractive manufactur-
ing methodologies, such as traditional
machining.” ASTM F3301 - 18 is a post-
AM processing standard.
Table 1 shows examples of AM standards
for titanium and nickel alloys fabricated
using the DMLS powder-bed laser method.
While various corrosion-resistant stainless
steels can be 3D printed with laser and
e-beam systems, the same approach
to the standards and certification pro-
cess will be required for the adoption of
AM-manufactured flow and pressure meters
and related corrosion-resistant alloys.
Pressure and flow sensors
Figure 1a shows how a stainless steel pres-
sure sensor combining the sensor element
and fluidic package with its male pipe thread
fitting and hex nut can be 3D-printed. After
post-print polishing of the diaphragm, the
device can be used for fiber optic pressure
sensing. Figure 1b shows that a patterned
thin or thick film circuit can be fabricated
on a flat, polished steel surface, in this
case, a piezoresistive Wheatstone bridge
for a pressure sensor capable of operating
in chemically aggressive applications.2 The
fluid under test is exposed only to the oppo-
site side of the metal diaphragm, keeping
the electrical sensing circuits safe.
Industrial resonant Coriolis mass flow
sensors are traditionally made from stain-
less steel or titanium tubing/pipe and
require multiple welding steps to fully
assemble the final product. 3D print-
ing offers a method of reducing the part
count of stainless or titanium tube-based
sensors by combining the resonant tube
with some of the packaging elements. A
wide array of small (millimeter-long tubes)
or larger macro size (meter-long tubes)
resonating flow sensors can be fabricated
using this technique.
Figure 2, on the left side, shows a small
titanium 3D-printed resonant sensor, which
combines the two resonating tubes with the
package frame, buried U-shaped return flow
channel and female threaded fluid fittings in
a single piece. These resonant devices can
Flow Control
measure mass flow rate, fluid density and
binary chemical concentration via density.
Figure 2, on the right side, shows a single
tube torsional mode balance Coriolis mass
flowmeter prototype made with laser-based
AM. Figure 2 demonstrates that flange or
threaded fittings can be combined along
with the resonating tubes and other struc-
tural housing and mounting elements into
a single printed piece.
3D printing allows new concepts to be
quickly evaluated without the delays and
costs often encountered in molded prod-
ucts for both plastic molding and metal
casting. The size of a 3D-printed Coriolis
mass flowmeter would only be limited by
the printer, and a wide variety of large and
micro printing systems have been and
are being developed and commercialized.
Size capabilities of
3D metal printing
While most 3D-printed metal devices are
in the 3 to 15 centimeter range, on the
large end of the scale, Lockheed-Martin
recently printed the domed ends of a titani-
um satellite fuel tank with e-beam printing.3
The metal domes had a diameter of 1.16
meter and reduced metal scrap by 80 per-
cent more than machining. Demonstrations
of metal printing of 2-meter-long parts have
also been demonstrated using the powder-
fed laser melt EFESTO printer.
The smaller 3D-printed metal systems
under development are leveraging years of
work in the 1980s on metal inkjet printing
for hybrid ceramic circuits4, metal print-
ing on porcelain-coated steel substrates5,
atomic force microscopy (AFM) and electro-
plating-based micromachining, often called
LIGA or Lithographie, Galvanoformung,
Abformung in German.6 LIGA involves the
electroplating of metal structures in a pho-
toresist mold and has been used to make
fuel injector nozzles and sensors such as
accelerometers and gyroscopes in the auto-
motive field. The smallest 3D-printed metal
structures use metal-containing solutions
such as metallo-organics in a solvent or
metal sulfates in an acidic plating solution.
Caltech has printed submicron-sized nickel
lattices7, and the FluidFM system has been
able to print copper cantilevers and probes
that are 1 to 100 microns in width.8 Further
www.flowcontrolnetwork.com
work is needed before
these methods are ready
to print micro flowmeters
or pressure sensors with
corrosion-resistant alloys.
A wide AM metal feature
size range of 1 microm-
eter to 2 meters allows
the majority of chemical
process and automotive
flow sensor sizes and flow
rates to be covered with
this promising manufac-
turing method.
Conclusion
Additive manufacturing of corrosion-resis-
tant metals has developed to the point
where pressure and flow sensors for pro-
cess control can begin to use this new tech-
nique. The materials used for 3D printing
are only limited by what metal or alloy can
be either powdered or formed into wire,
which opens up for chemical process and
automotive applications in addition to aero-
space and medical applications already in
use. Quality standards have been devel-
oped for many of the 3D-metal printing
alloys and processes, and emerging meth-
ods have demonstrated printed metal parts
in sizes from microns to meters, enabling
a range of products. FC
References
1. E. Matias, B. Rao, “3D Printing: On its
Historical Evolution and the Implications
for Business,” 2015 Proceedings
PICMET, pp. 551-558, (2015).
2. H. Shioiri et al., Method for
Production of Silicon Thin Film
Piezoresistive Devices,” US Patent
4,657,775, (1987).
3. T. Vialva,” Lockheed Martin pro-
duces its largest 3D printed parts
for space,” 3D Printing Industry, July
(2018). https://3dprintingindustry.
com/news/lockheed-martin-produces-
its-largest-3d-printed-parts-for-
space-136207/.
4. R. Vest, E. Tweedle, R. Buchanan,
“Ink Jet Printing of Hybrid Circuits,”
International Journal of Microcircuits
and Electronic Packaging 6(1), pp.
261-267, January (1983).
Figure 2.
(Left) 3D-
printed metal
resonant
density
sensor and
(right)
Coriolis mass
flowmeter
prototype
5. D. Sparks and G. Vest, "Copper Films
from Aqueous Solutions of Copper
Nitrate Trihydrate," Thin Solid Films,
vol. 200, p. 77, (1991).
6. D. Sparks, M. Chia, G.Q. Jiang,
“Cyclic Fatigue and Creep of
Electroformed Micromachines,”
Sensors and Actuators A, 95(1),
pp. 61-68, (2001).
7. R. Perkins, “New Process allows 3-D
Printing of Nanoscale Metal
Structures,” Caltech, Feb. (2018).
ht tp:// w w w.caltech.edu /news /
new-process-allows-3-d-printing-
nanoscale-metal-structures-81373.
8. L. Hirt et al., “Template-Free 3D
Microprinting of Metals Using a
Force-Controlled Nanopipette for
Layer-by-Layer Electrodeposition,”
Adv Mater. 28(12), pp. 2311-2315,
March (2016).
Doug Sparks is the presi-
dent of M2N Technologies
LLC and has worked for
many years with pressure
and Coriolis mass flow sensors as well
as MEMS sensors such as gyroscopes
and accelerometers. Most recently, he
was the CTO at Hanking Electronics,
founded a microsensor packaging com-
pany called NanoGetters and worked in
automotive sensors with Delphi. Sparks
holds a Ph.D. in materials engineering
from Purdue University.
February 2019 | 25
Features: System Integration

Case study: OEMs outsource critical aspects

of fluid handling systems
Leading OEMs turn to contract manufacturers that can combine
engineering, manufacturing and supply chain expertise to deliver
complete systems that lower costs.
By Jeff Elliott

F
or equipment designers in pro-
cessing industries, there are
aspects of a system that are more
functional in nature and yet still critical. how much engineering and design sup-
This includes gas, fluid and chemical
handling systems that play an integral
role in equipment that extracts, dis-
penses, blends or controls temperature,
among others.
For these aspects of the system, origi-
nal equipment manufacturers (OEMs)
face a critical business decision: whether
to fully engage as a manufacturer or to
outsource certain or all aspects to trusted, ment,” Medhurst said, explaining that
qualified contract manufacturers. By
doing so, they expect to control and even
lower production costs.
However, within the For large OEMs ...
category of contract
manufacturing, there having the ability to
can be a broad range offload some of the
of capabilities. Some
shops focus solely on “detail work” allows
build-to-print projects, key personnel to
often in niche catego-
ries such as piping or concentrate on more pieces of the project,
sheet-metal work. On important functions.
the other end of the
spectrum are compa-
nies that offer a more
diverse range of capabilities, complete
supply chain management and engineer-
ing services.
According to Jason Medhurst of Aztech
Controls, even companies that decide
to outsource may not have the in-house
expertise to assemble and, in some cases,
complete the drawings for a system or exe-
cute the required change control. For this
reason, there are benefits to a more full-
service approach that includes engineering.
“The truth is, OEMs don’t always know
port they actually need,” said Medhurst.
“They’ll ask us to build a system and say,
‘we’ve engineered it for you,’ and when
we get in there, we discover the design
is in its infancy.
“In other cases, we receive well-
developed drawings and the engineering
requirements are minor. Then, we might
help them with supply chain manage-
this can include sourcing, purchasing
and holding in inventory all the individ-
ual component parts of
the system.
With this type of sup-
port, OEMs are free to
focus on higher revenue
and proprietary aspects
of their system.
“The moment the
OEM starts retaining
they are not fully utilizing
everything a contract
manufacturer can do for
them,” said Medhurst.
“Then they end up still being part of the
project they are trying to offload.”
Supply chain management
at Kurita America
For large OEMs, outsourcing frees up
valuable resources: time and attention. OEMs can outsource
aspects of the mechanical,
The ability to offload some of the “detail electrical and control
work” allows key personnel to concentrate system to subcontractors.

26 | February 2019 Flow Control


on more important functions such as cli-
ent relations, scheduling and managing
the budget.
“Outsourcing opens up a lot more time
for me to focus on other areas of the proj-
ect instead of having to worry about some
of the minor details that eat up valuable
time,” said Tony Harlan of Kurita America,
a large supplier of industrial water treat-
ment systems.
Kurita America’s industrial water treat-
ment solutions range from chemicals
to custom-designed and constructed
water treatment, reuse and reclama-
tion systems, as well as operation and
www.flowcontrolnetwork.com
(Left) OEMs turn to contract manufacturers
that can combine engineering, manufacturing
and supply chain expertise to deliver complete
systems that lower costs.
(Below) Outsourcing complete systems, like
this pump skid, frees up time and resources.
All images courtesy of Aztech
maintenance services. Given the nature
of water treatment systems, no two com-
pleted systems are exactly alike. As a
result, every system must be engineered
to meet the requirements of the indi-
vidual customer.
However, to create these systems, it
is standard practice for companies like
Kurita America to outsource aspects of
the mechanical, electrical and control
system to subcontractors.
“Typically, we would purchase all the
valves, pumps — whatever was going on
that skid — and only ask the fabrication
shop to do the assembly,” said Harlan.
February 2019 | 27
 There were several motivations for this
approach, including the belief that
purchasing the parts would ensure the
best price without markups. However,
this logistical work came with additional
costs that were not considered, includ-
ing the time and effort to create each
purchase order, deal with invoices, man-
age and store parts inventory, ensure
it was shipped properly and arrived as
scheduled at the fabrication shop, and
deal with any necessary returns.
Aztech Controls pitched Kurita on the
concept of building the entire system
for them, including sourcing all the
components. Aztech Controls, founded
in 1986 as a distribution and repre-
sentative company for products used
for wastewater and other processing
industries, offers full engineering and
manufacturing capabilities to build-to-
print or design-and-build complete sys-
tems from scratch. Kurita felt that the
28 | February 2019
company’s long history as a distributor
in the industry gave them confidence
that Aztech Controls could source the
parts at a reasonable cost.
The project was a success, and Harlan
said that in the past year, Kurita America
has worked with Aztech Controls to pro-
duce six or seven additional skid-mounted
subsystems.
Advanced chemical blending
David Radnich, a retired engineer,
recounts a project for something that
he said is a bit of a rarity in the industry
— a just-in-time chemical blending and
delivery system.
The project was part of a cost-cutting
initiative to eliminate the need to pur-
chase an expensive chemical blend for a
large semiconductor chip manufacturer.
The company had determined it could
save money by blending the chemicals
on-site, since the three constituent
chemicals were inexpensive. Radnich
was asked to participate on the team
that would design and build a prototype
system from scratch.
“They didn’t have the bandwidth to
build advanced systems like that com-
pletely in-house,” said Radnich. “They
certainly could do it, but they want to
run more of a streamlined operation, so
for a one-off like that, better to go to a
trusted source.”
After working up an initial design con-
cept, he contacted Aztech Controls.
Together, the two groups quickly com-
pleted the design, and then the contract
manufacturer proceeded to build the
entire system at its facility in Arizona. The
cost-effective prototype was completed
in only a few weeks and was integrated
easily into the system. Radnich said the
prototype was tested over six months and
worked flawlessly.
The next step was a full-scale version
of the system. Aztech Controls delivered
it in six weeks, as opposed to the typical
lead time of six months to a year from
other vendors.
“The system from Aztech Controls
literally had no capacity constraints,
no scheduled invasive PMs [preventive
maintenance] and the cost of ownership
once it was running was almost nothing,”
said Radnich.
Radnich said his team couldn’t have
designed and built the system without
the help of Aztech Controls. To date,
the system has been working for almost
seven years without issues. The proj-
ect was also a success in terms of the
cost savings the company was hoping
to achieve.
“It was a cost savings from an equip-
ment standpoint, installation standpoint
and operational standpoint,” said Radnich.
Visit aztechcontrols.com to find more
information. FC
Jeff Elliott is a Torrance, California-based
technical writer. He has researched and
written about industrial technologies and
issues for the past 20 years.
Flow Control
Trade Shows & Events
ProFood Tech provides solutions
for food and beverage processing
P
roFood Tech, a solutions and net-
working event for the food and
beverage processing industry, will
be held at McCormick Place in Chicago
on March 26–28. Packaging Machinery
Manufacturers Institute (PMMI), the
Association for Packaging and Processing
Technologies, Koelnmesse and the
International Dairy Foods Association
(IDFA) arranged the biennial event that
began in 2017.
Approximately 400 solutions suppliers
spanning 10 food and beverage markets
will present their technologies and solu-
tions, as well as educate attendees on
new regulations in the food and bever-
age packaging and processing industry.
Machinery from 450 manufacturers will
be on display.
Companies will also exhibit solutions for
heat transfer, pump systems and power
management, as well as innovations in
processes such as clean-in-place (CIP),
sanitizing, piping and filtration methods.
Education opportunities
Free sessions, produced by IDFA, are
contained within three venues on the
show floor: Impact Zone, Disruption Zone
and Innovation Zone.
Impact Zone encourages attendees to
listen and participate in discussions
based on case studies in processing
plants across the food and beverage
industry. Topics include:
• Strategies for Surviving Food Recalls
• Navigating Cybersecurity and the
Internet of Things (IoT)
• Can the Food Industry Survive
Climate Change?
• Transparent and Truthful Labels for
Educated Consumers
www.flowcontrolnetwork.com
EXHIBITION SCHEDULE
Tues., March 26, 10 a.m.–4 p.m.
Courtesy of PMMI
Wed., March 27, 10 a.m.–4 p.m.
Thurs., March 28, 10 a.m.–4 p.m.
profoodtech.com
• Trade and Tariffs — What’s Next? • Aquafine
• Is Artificial Intelligence (AI) the • Axiflow Technologies Inc.
Answer to Workforce Shortages? • Cablevey Conveyors
• Clean Water Technology
Disruption Zone allows attendees to • Donaldson Company Inc.
learn about implementing disruptive tech- • DSO Fluid Handling Co. Inc.
nology. Topics include: • Emerson
• When did “Processing” Become • Eriez
a Bad Word? • Evoqua Water Technologies
• Is Blockchain the Answer or the • Flottweg Separation
Question? Technology Inc.
• Probiotics and Protein: Two • Global Water Engineering N.V.
Exploding Opportunities • Hartford Control Limited
• Consumer Trends Are Dictating • HRS Heat Exchangers
the Future • Krohne
• E-Commerce: Is It Good or Bad? • Netzsch Pumps North America
• How Can We Leverage Our Efforts • Rotex Global
on Food Waste? • Schenck Process
• Semi-Bulk Systems Inc.
Innovation Zone is a place to discover • Separators Inc.
technological advances, formulations and
ideas. Sessions will answer questions and The 50,000-square-foot Dairy Pavilion,
solve processing issues. hosted by IDFA, replaced its dairy show.
The IDFA Knowledge Hub is also a free In this section of the show floor, dairy
education section that will host discus- processors network with dairy industry
sions throughout the show in designated suppliers and explore crossover tech-
areas on the show floor. nologies from other industries.
Another educational conference within
ProFood Tech is the 2019 Cold Pressure Awards and networking
Council Annual Conference sponsored by ProFood Tech offers networking oppor-
Cold Pressure Council. It is focused on tunities through receptions and award
research, benefits and trends in high- ceremonies. The Women’s Packaging &
pressure processing (HPP). It will provide Processing Leadership Network Breakfast
practices, market trends, packaging brings together industry members to
material insights and tips for packaging help encourage and advance women’s
HPP products. Attendees can opt into this careers in packaging and processing.
event during the ProFood Tech registration The Emerging Leaders Network (ELN),
process for an additional cost. a group of processing and packaging
professionals who work to advance the
Exhibitors industry, will host a networking event at
Some exhibitors include: ProFood Tech for current and past ELN
• ABB Inc. participants. FC
February 2019 | 29
Featured Products

Send products for consideration in this section

to mrogers@endeavorbusinessmedia.com.

Pump calculator Blowdown valve

Bredel’s total cost of Conval’s Clampseal blowdown service

ownership (TCO) calculator valves provide control for continuous or
supports existing users and tandem boiler or turbine blowdown and
new customers in the hose bottom blow-off service. They feature
pump specification process. a one-piece gland, which eliminates
Users enter the necessary the potential for stem damage. With
parameters including the leakproof bonnet, the cartridge-style
flow rate and pressure and packing chamber allows access
whether they are using or considering air-operated double to valve trim for inspection and
diaphragm and progressive cavity pumps. Then they are maintenance. The pressure seal fixed
given a direct comparison to show which model and size backseat helps ensure a positive internal stop for the
of Bredel pump will deliver optimal pumping and cost valve and stem and disc assembly. The valves are fully
savings for the application. serviceable inline using standard Conval tools.

Pressure transmitter Compact transmitter

Emerson’s Rosemount 3051HT Endress+Hauser’s Liquiline compact

Hygienic Pressure Transmitter is
ideal for hygienic applications in
which regular CIP/SIP regimens
can cause measurement devices
to become unstable and batch
quality to deteriorate. It uses
pressure sensor technology and
a hygienic design to maintain
measurement stability for up to five years, enabling
repeatable batch quality and high yields. It stabilizes
quickly after cleaning cycles, returning to its
calibrated settings.
CM82 transmitter accepts
pH, ORP, pH/ORP,
conductivity, oxygen
and chlorine sensor
signals from the Memosens sensor platform. Its housing
measures 11 cm long and 2 cm wide, yet it is a fully
developed multiparameter transmitter with access
available via 4-20mA HART or Bluetooth from any iOS
or Android device. When a CM82 measuring point
is configured, all settings are saved in the compact
transmitter. It can be connected directly to a control
component, such as a PLC.

Coriolis mass flowmeter Modulating actuator

KROHNE’s OPTIMASS 6400 twin Rotork’s CMA range of compact

bent tube Coriolis mass flowmeter
has a new signal converter that
features advanced device and process
diagnostics. It is approved
for custody transfers of
liquids and gases, making
it ideal for process industries
and applications like LNG, CNG or
super-critical gases in terminal or
storage/bunkering. It features entrained gas management
(EGM), with no loss of measurement with gas
entrainment up to 100 percent of volume.
modulating actuators offers new sizes
for larger linear control valves. The
new actuator is capable of a maximum
4,500 lbf (20 kN) seating thrust. The
new sizes increase the CMA range
modulating thrust performance to 3,000
lbf (13 kN) with a 114.3 mm stroke length
for automation of larger valves with higher
pressure ratings. CMAs can handle extreme temperature
swings and corrosive environments. The optional
Reserve Power Pack uses supercapacitors to provide
the actuator with stored energy.

30 | February 2019 Flow Control

 Connect
SOLUTIONS FOR FLUID MOVEMENT, MEASUREMENT & CONTAINMENT

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Festo Corporation ........................................................................... 8 Spitzer and Boyes LLC .................................................................. 22

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Bearing technology
changes in the fluid
Virtual reality and augmented reality are the latest
handling industry |
ow.ly/bP4D30n6O8F in the series of technological waves sweeping across
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Technology advances in
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32 | February 2019
 TAKING B2B MEDIA
TO NEW HEIGHTS
The Process Flow Network is now a
part of Endeavor Business Media.

Learn more at EndeavorBusinessMedia.com

www.processingmagazine.com FEBRUARY 2018

SPECIAL
SECTION
FOOD & BEV
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Solutions
FEATURED PRODUCTS for Industri
al Water
Advanced planetary mixer Managemen
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ID MO VEM EN T The Ross Test & Development Center added a 4-gallon planetary dual dis-
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perser (PPDM-4) equipped with two high-viscosity blades and two high-
speed dispersers, now available for no-charge demonstrations. All four agita-
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rapid powder wet-out and deagglomeration. Ideal for mixing
thick slurries and highly illed pastes, the mixer is designed for
vacuum operation and includes a jacketed mix vessel.

Charles Ross & Son Company

www.mixers.com

Wireless vibration sensor

Fluke’s 3560 FC wireless sensor provides continuous, automated vibration
screening to monitor equipment health. The sensor wirelessly and remotely

VACntenance Coolin
COVER sERIES P10 captures simple vibration screening data on imbalance and misalignment.
Precise placement increases accuracy and

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System Mai ets
Food & Beverage
High-pressure processing, dry
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systems help food processors
achieve sanitary requirements,
improve productivity and extend
reduces the time it takes to screen an asset.
The data generated from the sensors is trans-
mitted and stored on Fluke Connect Condition
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teams to remotely monitor asset health.
tower g
protects ass equipment life. Fluke Corporation
monitoring
eficiency
www.luke.com
Effective
Twin-screw feeder
The Model TSF twin-screw feeder from Best Process Solutions is designed for precise batching ONLINE EXCLUSIVE
and weighing applications. The feeder’s dual-helix design combines fast, high-volume illing with
accurate dribble low at the end of the cycle. Its compact design is ideal when
limited space prohibits multiple individual screw units. Two helixes — 1½"
and 4" in diameter — are mounted on an 18" x 22" hopper.
SELECTIN
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Flexible coating What to expect from industrial
technology in 2018 PUMP DESISTANT
Stronghold Coatings has a new permanently elastic, two-component polyurethane elastomer SIGNS
Also Inside that is designed for the sealing and repair of pumps and lexible products like natural and A Q&A with GE Digital’s general
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No. 1 JANUARY/F
• Vol. XXIV, 10:54 AM EBRUARY
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12/11/17 2018 | WATERTEC
ontro HONLINE.C
www.flowc OM

1/11/18
8:53 AM
 Does your piping
configuration
reduce the
accuracy of your
custody transfer
measurement?

Designed to nearly eliminate sensitivity to

upstream piping and installation effects,
the new Daniel 3418 8-Path Gas Ultrasonic
Flow Meter by Emerson delivers superior
performance in custody transfer applications.
The intuitive, proprietary design makes no
compromises and:

• Passes all mild and severe perturbation

tests without exception and without
flow conditioning
BEST IN CLASS
• Reduces piping design requirements MEASUREMENT ACCURACY
and capital costs without OIML Accuracy Class 0.5 certified
compromising accuracy with only five diameters of
upstream piping required and
• Improves line balance no flow conditioner.

For product information:

www.Emerson.com/UltrasonicFlowMeters

The Emerson logo is a trademark and service mark of Emerson Electric Co. The Daniel name and logo are trademarks of Daniel Industries, Inc. ©2019 Emerson Electric Co.