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

www.flowcontrolnetwork.com
 Connect to quality at
EASA
CONVENTION
Page 30

PUMP
Reliability
Motors contribute to
dependability & efficiency
Also Inside

Innovation Awards nominations

Bearing trends & fundamentals

Enhanced oil recovery seals

JUNE 2018 • Vol. XXIV, No. 6

www.flowcontrolnetwork.com

Connect
SOLUTIONS FOR FLUID MOVEMENT, MEASUREMENT & CONTAINMENT

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Table of Contents | January 2019 • Vol. XXV, No. 1

Cover Story
10 The effects of temperature and
pressure on fluid density
By Norman Glen, TUV SUD NEL
Knowledge of the density of a fluid and its variation
with temperature and pressure is vital for many flow
measurement applications.

Features
14 API 18.2: Ensure safety while
providing better level and volume
10
measurement options
By Tom Wienke, Rosemount Level Products at
Emerson Automation Solutions
Automating level measurements keeps workers
off tanks to ensure their safety while improving
quality, consistency and accuracy of custody
transfer measurements.

18 Connected and monitored assets

improve safety and efficiency 14 18
By Alex Desselle, Fluke Accelix
IIoT brings new possibilities to the plant floor for
personnel and equipment safety, asset health
and time efficiencies.
Departments
21 Case study: Ultrasonic flow metering
improves energy efficiency 4 From the Editor
By Izzy Rivera, FLEXIM, and Jack Sine
To meet environmental goals, a university upgrades 6 News & Notes
its HVAC monitoring system.
8 Application Corner & Quiz Corner
Best Practices & Applications 28 Trade Shows & Events
24 Performing a storage tank
risk assessment 30 Featured Products
By Dean Mallon, Endress+Hauser
Petroleum storage tanks should be ready for 31 Advertiser Index
updates to API 2350.
32 FlowControlNetwork.com
Cover: EduardHarkonen/iStock

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2 | January 2019 Flow Control

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 VICE PRESIDENT & GROUP PUBLISHER
MICHAEL C. CHRISTIAN
mchristian@endeavorbusinessmedia.com
EDITOR IN CHIEF
MOLLY ROGERS
mrogers@endeavorbusinessmedia.com
CONTRIBUTING EDITORS
AMY W. RICHARDSON
arichardson@endeavorbusinessmedia.com
MARIE MCBURNETT
mmcburnett@endeavorbusinessmedia.com
GROUP ASSISTANT EDITOR
DANIEL GADDY
dgaddy@endeavorbusinessmedia.com
COLUMNIST
DAVID W. SPITZER
From the Editor Alacatr/iStock ART DIRECTOR
JULIE WHITTY
PRODUCTION MANAGER

I
hope you had a wonderful holiday
season and your new year is off to
a good start.
We kick off 2019 with this issue of
Flow Control, bringing you solutions to
expected in the fifth edition soon to be AMANDA PORTER
released. Among the recommended prac- aporter@endeavorbusinessmedia.com
tices is implementing and maintaining a DISTRICT MANAGER
risk assessment system for petroleum JAY HAAS | 205-572-1058
storage tanks, and Mallon details some jhaas@endeavorbusinessmedia.com

fluid handling challenges. Our focus on suggestions. ACCOUNT MANAGER

the oil and gas sector begins with the In this issue, we also bring you a case ADDISON PERKINS | 205-861-5303
aperkins@endeavorbusinessmedia.com
cover story in which Norman Glen with study on an upgraded HVAC monitoring
NATIONAL ACCOUNTS MANAGER
TUV SUD NEL discusses problems with system. FLEXIM shares how they col-
JIM SEMPLE | 908-963-3008
the use of the standard method of cal- laborated with a university on choosing jsemple@endeavorbusinessmedia.com
culating oil density at elevated pressures ultrasonic flowmeters, and as a result, ACCOUNT MANAGER
and explains how knowledge of the den- helped the university not only improve LISA WILLIMAN | 205-332-5915
sity of a fluid and its variation with tem- energy efficiency but also help it become lwilliman@endeavorbusinessmedia.com
perature and pressure is vital for many a leading green campus. DIGITAL SALES LEAD
flow measurement applications. If you’re looking for more HVAC-related MICHAEL RING | 347-365-0641
mring@endeavorbusinessmedia.com
In our next featured article, Tom Wienke solutions, be sure to read our AHR Expo
MARKETING MANAGER
of Rosemount Level Products at Emerson preview in this issue before you head out
NICK PHILLIPS
Automation Solutions compares two level to Atlanta on January 14–16.
DIGITAL OPERATIONS MANAGER
technologies that measure the oil-water I hope you enjoy reading this issue MARY BETH ROMANO
interface together with the surface level — of Flow Control and have a prosperous AUDIENCE DEVELOPMENT MANAGER
magnetostrictive and guided-wave radar year ahead. ANNA HICKS
— for custody transfer applications. As SUBSCRIPTION & REPRINT REQUEST
Wienke explains, automated methods Sincerely, flowcontrol@omeda.com
rather than manual help address safety
CORPORATE TEAM
concerns for workers, operating under
CHIEF EXECUTIVE OFFICER
the standard API 18.2. CHRIS FERRELL
In Best Practices & Applications, Dean Molly Rogers CHIEF OPERATING OFFICER
Mallon of Endress+Hauser discusses mrogers@endeavorbusinessmedia.com PATRICK RAINS
another standard, API 2350, and what’s @FlowControl_Mag EXECUTIVE VICE PRESIDENT
SCOTT BIEDA

EDITORIAL ADVISORY BOARD

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 | January 2019 Flow Control

 subscribe today.
Flow Control is the voice of fluid handling professionals
in the Process Flow Network, which provides solutions
for the process industries and includes Processing
and Water Technology.

Essential
PROCESS
CONTROL
Automation isn’t optional

Also Inside

Flowmeter accuracy

Tank level measurement

Peristaltic pump safety

MAY 2018 • Vol. XXIV, No. 5

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FC_0518_Cover.indd 1 4/5/18 12:42 PM

flowcontrolnetwork.com/subscribe
News & Notes
Company news
MMEX Resources selects
Blanchard Industrial as EPC
contractor for Texas refinery
MMEX Resources Corp., a development
stage company focusing on the acquisi-
tion, development and financing of oil,
gas, refining and infrastructure projects in
Texas and South America, and Blanchard
Industrial LLC (BIL), a provider of design,
engineering, procurement and construc-
tion (EPC) solutions, announced that
BIL will be the overall EPC contractor to
complete the detailed engineering and
construction of the planned Pecos County
Crude Distillation Unit refinery by MMEX.
MMEX announced plans to build a crude
oil refinery complex in the Permian Basin
Pecos County near Fort Stockton, Texas,
in two phases: phase 1 — a 10,000 bpd
crude distillation unit that produces diesel,
naphtha and residual fuel oil, and phase
2 — a full-scale crude oil refinery with
capacity of up to 100,000 bpd, producing
a full slate of refined products.
Tonalli awards contract to
Simmons Edeco for drilling
services in Mexico
SIMMONS EDECO, a supplier of onshore
drilling and workovers, wellhead mainte-
nance services and asset integrity solu-
tions to the global oil and gas industry,
announced it was awarded a contract
by Tonalli Energia S.A.P.I. de C.V to
provide drilling services in Mexico. The
contract engages SIMMONS EDECO
to support Tonalli’s onshore oil and
gas development Block 24. The Block,
known as Tecolutla, is in the Tampico-
Misantla Basin in the Mexican state of
Veracruz. SIMMONS EDECO will drill the
horizontal well 2310 TVD to a measured
depth of 3,750 meters by using Rig 836,
which recently drilled a number of wells
on the Amatitlan block in Mexico. To
support the Tonalli contract, SIMMONS
EDECO will draw upon specialist person-
nel and equipment located at its base in
Poza Rica, Mexico. This drilling project
represents the first time the company will
work on behalf of Tonalli Energia, a joint
venture between Mexican petrochemical
6 | January 2019
company Grupo IDESA and Canadian
oil and gas company International
Frontier Resources.
Motion Industries acquires
Hydraulic Supply Company
Motion Industries Inc., a wholly owned
subsidiary of Genuine Parts Company,
acquired Hydraulic Supply Company
(HSC). Execution of the transaction was
completed on Oct. 1, 2018. Founded in
1947, HSC is a full-service distributor,
offering customers more than 8,000
hydraulic, pneumatic and industrial
products. Its team of technicians pro-
vide services including hydraulic repair,
hose assembly and kitting, tube bending
and flaring, and manual valve assembly.
Headquartered near Miami, HSC serves
customers in industries from agriculture
to mining to transportation throughout
and beyond its 30-location footprint,
mainly in the southeastern U.S. It also
conducts international sales through
its office in Monterrey, Mexico. HSC
will operate as a vertical division within
Motion’s Conveyance Solutions Group.
NETZSCH becomes member
in Star Pump Alliance
NETZSCH Pumps North America became
a member in the Star Pump Alliance, an
organization that works to assist profes-
sional users of pumps in selecting pump
technology tailored to fit their specific
applications. NETZSCH Pumps North
America offers its expertise and experi-
ence in assisting professional pump users
to find the right solution for their applica-
tion via the Star Pump Alliance. The Star
Pump Alliance is backed by numerous well-
known, experienced pump manufacturers,
market and technology leaders. The mem-
bers of the Star Pump Alliance provide
help for professional pump users in find-
ing the right solution by contacting these
users directly after they send their inquiries
through the Star Pump Alliance Portal. The
portal offers extensive information about
segments of industry, specific applica-
tions and technologies as well as tools
for the individual selection of pumps, and
a digital technology selector with access to
the product portfolios of different brands.
This selector proposes to website visitors
one or several suitable pump technolo-
gies for each specific application on the
basis of the application characteristics the
users have entered. Specific pump tech-
nologies are recommended according to
verifiable technical criteria, and users can
continuously observe the effect of their
data entries on narrowing down the search
result in the selector.
Almatec relocates
headquarters
Almatec, part of PSG, a Dover company
and manufacturer of air-operated dou-
ble-diaphragm (AODD) pumps and
quaternary diaphragm pumps, moved
into its new corporate headquarters in
Duisburg, Germany. The headquarters
will accommodate the growing busi-
ness by providing 17,200 square feet
— roughly 70 percent more space —
including a much larger manufacturing
facility and an ISO Class 7 cleanroom.
MFG Chemical upgrades
newly acquired Texas plant
with new reactors
MFG Chemical is upgrading its Pasadena,
Texas, plant that the company acquired
March 2018. The acquisition of the
Pasadena plant, which sits on 24.5
acres, combined with the company’s
three plants in northwest Georgia, make
MFG Chemical one of America’s largest
consumers of maleic anhydride. The
Pasadena plant improvements, sched-
uled for completion by the end of the
first quarter 2019, entail a multimillion-
dollar investment. Improvements include
debottlenecking and new capacity addi-
tions, including two new reactors; one of
which is 20,000 gallons.
CORTEC receives SIL
certification for CRV
pressure relief valves
and trunnion ball valves
CORTEC, a manufacturer of high-quality
API valves and manifolds, received a
Safety Integrity Level (SIL) certification
on its model series CRV pressure relief
valves and model series D and LD trun-
nion ball valves, which verify the safety
Flow Control
of the products. The SIL certification
provides a quantification of the reduced
likelihood of a hazardous event from
occurring and assures that an indepen-
dent third party reviewed the safety of
the design and function of the product.
Historically, CORTEC’s product line has
been heavily upstream-focused, but the
addition of SIL-capable products coupled
with expanding controls package offerings
will help expand the types of applications
CORTEC can serve.
Mueller to acquire
Krausz Industries
Mueller Water Products Inc. signed an
agreement to acquire Krausz Industries,
a manufacturer of pipe couplings, grips
and clamps, for $140 million. Krausz
Industries provides proprietary pipe
couplings, grips and clamps under the
HYMAX brand for the global water and
wastewater industries. The company is
headquartered in Tel Aviv, Israel, with
manufacturing operations in Israel, dis-
tribution facilities in the U.S. and 300
employees worldwide. Krausz had net
sales of approximately $43 million in
2017 with approximately 75 percent of
its sales generated in North America.
Augury and PSG partner
to bring predictive analytics
to chemical processing
Augury, an AI-based mechanical diagnos-
tics provider, and PSG, a manufacturer of
pumps, systems and related flow control
solutions, have partnered to provide cus-
tomers with data-driven insights about
how pumps and the systems they power
are managed and maintained. According
to the company, the partnership will
enable existing and future PSG customers
to benefit from an increase in efficiency,
uptime and resiliency through new ser-
vices, powered by Augury’s IIoT-enabled
continuous diagnostics and predictive
analytics technology.
Gardner Denver acquires
DV Systems
Gardner Denver, a provider of flow
control and compression equipment,
acquired DV Systems Inc. Based in Barrie,
www.flowcontrolnetwork.com
Ontario, DV Systems is a manufacturer of
rotary screw and piston compressors and
associated aftermarket parts. Gardner
Denver officials said the move will pro-
vide further access to the Canadian
market and expand the company’s
distribution network as well as its com-
mercial, operational and research and
development capabilities.
People news
Cleansorb appoints two new
product support scientists
Cleansorb, a provider of chemical well
treatments that enhance hydrocarbon
production for the international oil and
gas industry, appointed two new product
support scientists to its product support
team. The new scientists earned degrees
in biomedical science and chemistry with
nanotechnology, providing additional
expertise to the Cleansorb team. The
product support team is based at
Cleansorb’s global headquarters in
Guildford, England, where the new sci-
entists work in the purpose-built wet
lab with expert chemists and liaise with
field engineers to formulate and further
develop custom reservoir chemistry treat-
ments, particularly for filter cake cleanup,
stimulation and sand consolidation.
FSA appoints Robert S.
Coffee as president of the
association
The Fluid Sealing Association (FSA)
appointed Robert (Rob) S. Coffee as
president of the association. He is cur-
rently the vice president of sales and
marketing for Proco Products Inc. in
Stockton, California. Coffee has been in
the expansion joint industry since 1980,
working part-time after high school at
Pathway Bellows. During his tenure at
Pathway, he performed duties inside
customer service for fabric expansion
joints and then industrial dampers. In
1990, he transitioned to field sales-
man with responsibility for northern
California, Oregon and Washington. In
1994, Coffee joined Proco Products
as marketing manager. As vice presi-
dent of sales and marketing (2007),
his duties have included conducting
engineering seminars and sales train-
ing throughout U.S. and Canada, bring-
ing more than 30 years of application
experience.
Weir Oil & Gas hires
new president of
pressure pumping
Weir Oil & Gas hired David Paterson as
president of pressure pumping. Based
in Fort Worth, Paterson will lead Weir’s
Oil & Gas pressure pumping business,
overseeing the strategic direction of all
global operations, manufacturing and
service footprint. Paterson has more
than 20 years of experience in the oil
and gas sector. Prior to joining Weir,
he was president of artificial lift at
Schlumberger where he was responsible
for the global financial performance,
strategic direction and service delivery
of the artificial lift segment, leading over
3,000 employees across the globe.
Paterson holds a Bachelor of Science
and a Master of Science in offshore
engineering from The Robert Gordon
University in Aberdeen, Scotland. FC
Send news and events for consideration
to Molly Rogers at mrogers@
endeavorbusinessmedia.com.
Upcoming events
AHR Expo
Jan. 14–16
Atlanta
ahrexpo.com
ARC Industry Forum
Feb. 4–7
Orlando
arcweb.com
Hydraulic Institute Conference
Feb. 24–28
St. Petersburg, Florida
pumps.org
ProFood Tech
March 26–28
Chicago
profoodtech.com
January 2019 | 7
 Application Corner
By David W. Spitzer

Lessons learned
E
very now and then, a published
article or internet discussion pro-
vides insight into what is really
going on. Often these articles entail try-
ing to technically defend the technically
indefensible.
For example, every 10 years or so, I
am asked to review an article about vari-
able speed drives that selectively applies
the Affinity Laws to incorrectly calculate
energy savings. My recommendation is
usually against publication, but the author
typically modifies the article to make his
or her analysis technically correct within
a small set of uncommon applications.
The information that I draw from these
experiences is that the author may be
effective in his or her work in the field, but
does not really understand the nuances.
One can learn a lot by thinking some-
thing through, but often, more is learned
by making mistakes and observing the
consequences. When possible, it is better
to learn from someone else’s mistakes
instead of your own mistakes. However,
humans generally do not like to publicize
their mistakes (even if it will help others),
so opportunities to learn from others’ mis-
takes can be limited. The good news is
that this seems to be changing because
younger workers are more communica-
tive and collaborative than those nearing
retirement.
The importance of technical correct-
ness cannot be overemphasized when
it comes to technical writing. A few
technical errors might occur; however,
some may be beyond the author’s control.
Having written more than 10 books, more
than 400 technical articles and numer-
ous whitepapers for our clients, I suggest
that you read articles (including mine)
skeptically.
One should remember that lessons
are more often learned from mistakes
than from successes. However, as you
strive to improve plant performance, I
suggest that your goal be to know your
field well enough so your mistakes are
subtle and do not cause harm before
you fix them. This may require taking
calculated risks that you might want to
share with others — before and after
the fact. FC

Quiz Corner Which of the following can be used as a flow

calibration technique?
A. Compare a flowmeter with a flow C. Compare a flowmeter with a meter under test (MUT).
laboratory standard. D. Verify electronic adjustments (zero/span).
B. Compare a flowmeter with a master meter. E. Verify flowmeter dimensions.

C
omparing a flowmeter with an MUT (Answer C) is
incorrect because the flowmeter would be compared
with itself.
Comparing the flowmeter with a flow laboratory standard
(Answer A) and comparing the flowmeter with a master meter
(Answer B) are wet calibration techniques in which the fluid
actually flows through the flowmeter.
Verifying electronic adjustments (Answer D) and verifying
the flowmeter dimensions (Answer E) are dry calibration
techniques that are performed without flowing the fluid
through the flowmeter.
Additional complicating factors
Wet calibrations are usually more difficult to perform, but
they are generally more effective than dry calibrations.
However, dry calibrations are used extensively on some
flowmeter technologies, including the calibration of orifice
plate flowmeters for the custody transfer of natural gas. FC

8 | January 2019 Flow Control

 Dry calibrations are used extensively on some flowmeter
technologies, including the calibration of orifice plate flowmeters
for the custody transfer of natural gas.

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-
Precision Flow Control
sulting, distribution consulting and expert
witness services for manufacturing and
automation companies. Spitzer and Boyes
Demands Perfect Balance.
is also the publisher of the Industrial
Automation INSIDER. He has more than
40 years of experience and has written Quality
more than 10 books and 400 articles Our precise manufacturing
about flow measurement, instrumenta- and quality control process-
tion and process control.Spitzer may be es ensure flow control and
reached at 845-623-1830 or via spitzer- flow metering products that
andboyes.com. Click on the Products tab are accurate, durable and
to find his Consumer Guides to various trouble-free.
flow and level measurement technologies.
Repeatability
Lot after lot, time after time,
O’Keefe Controls products

Did you perform consistently and

reliably.

Dependability
know? Whether specifying our
standard or custom products,
Analytical SaaS O’Keefe Controls will provide
the solution you need, when
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based alternatives to legacy
solutions are predicted to
dominate the industrial sector
If it’s about precision, it’s O’Keefe.
due to the shift in customer
focus from instrumentation
800.533.3285
features to the ways in which
the technology can help
enhance business outcomes. Precision Orifices • Flow Controls • Check Valves
–Frost & Sullivan Visit us at www.OKeefeControls.com
frost.com

www.flowcontrolnetwork.com January 2019 | 9


The effects of
temperature and pressure
on fluid density
Knowledge of the density of a fluid and its
variation with temperature and pressure is
vital for many flow measurement applications.
K
By Norman Glen, TUV SUD NEL nowledge of the density of a fluid
and its variation with temperature
and pressure is essential for con-
version between mass and volume. This
is of particular importance in the oil and
gas sector where many flow measure-
ment systems make use of volumetric
flow measurement devices, but mass
is the quantity required for reporting
10 | January 2019
EduardHarkonen/iStock
production and for allocation in shared
transportation systems.
Furthermore, crude oil and petroleum
products are typically sold by volume at
reference conditions (e.g., 60°F and 0
psig or 15°C and 101.325 kPa); hence,
the effects of temperature and pressure
on fluid density (volume) are required
to convert from measured to reference
conditions.
Direct measurement of the density of
a fluid passing through a volumetric flow
measurement device will, in principle,
provide the lowest uncertainty when
converting to mass flow. However, if the
Flow Control
 were mainly derived from measurements
Accurate knowledge of the density of the fluid
made on samples from U.S. domestic oil
passing through the reference measurement system production in 1916.
and the device being calibrated is essential. A compressibility standard for hydro-
carbons was developed in 1945 for the
API, based on limited data obtained
temperature and pressure at the density- bar and the advanced multiphase facility mostly from pure compounds and lubri-
measuring device differ from those at planned to operate at up to 140 bar, the cating oils. In 1945, the U.K. Institute of
the flowmeter, errors will be introduced use of generic compressibility correction Petroleum (IP) also published VCF tables,
unless the temperature and pressure factors would lead to potential errors in and in 1952, the British and American
dependence of the fluid is sufficiently calculated oil densities in excess of 0.25 temperature correction factor tables were
and accurately known. percent, rather than the 0.02 to 0.03 joined together. These tables were called
The measurement task involved in percent required. the Petroleum Measurement Tables and
determining the effects of tempera- Correction factors to account for the were published jointly by the American
ture and pressure for all crude oils and thermal expansion of liquid hydrocarbons Society for Testing and Materials (ASTM),
refined products traded globally would were first formally developed by the U.S. the API and the IP. They are commonly
be immense. Therefore, alternative National Bureau of Standards in 1916. referred to as the 1952 Tables or “Blue
approaches have been developed, in The data used to develop these VCFs Book Tables.”
particular, correlation methods applicable
to generalized product groups. For crude
oil and refined products, the most widely
used approach involves the volume cor-
rection factors (VCFs) maintained by the
American Institute of Petroleum (API).
These factors are widely used through-
out the oil industry, including being pro-
grammed into the flow computers that
form a fundamental part of fiscal flow
measurement systems.
However, recent commissioning of the
new high-pressure single-phase oil cali-
bration facility at TUV SUD NEL’s elevated
pressure and temperature (EPAT) facility
has provided evidence of problems with
the use of the standard method of cal- Figure 1. An example of the percentage difference between the calculated and measured densities
culating oil density at elevated pressures. for one of the oils at 1 bar(a) for the three calculation methods. Figures courtesy of TUV SUD NEL
Significant bias errors were observed
when compared to traceable experi-
mental density measurement of the oil
samples concerned. This has potentially
wide-ranging impact across the entire
industry and requires urgent attention.
Accurate values of the densities of the
oils used in TUV SUD NEL’s flow measure-
ment facilities are essential for ensur-
ing that each facility meets its overall
accredited uncertainty. Previously, when
the facilities were operating at close to
ambient pressure, the use of generic
compressibility correction factors were
sufficient to account for the changes in
density with pressure. Now, with the wet
gas facility operating at up to 63 bar, Figure 2. The results for one of the oils at elevated pressure, plotting the percentage differences
the EPAT facility operating at up to 100 between the calculated and measured densities for each of the three calculation methods

www.flowcontrolnetwork.com January 2019 | 11

 Major revisions of the standard were
issued in 1980 and 2004. In 1981, a
revised compressibility standard was
developed. Although based on a broader
database, the limits of the experimental
data were from 681 to 934 kgm-3, 0°C to
150°C and 1 to 50 bar(a), but the stan-
dard allowed extrapolations, in particular,
up to 104 bar(a).
For the purpose of calculating VCFs,
the API method classifies petroleum
fluids as:
• Crude oils
• Refined products
• Lubricating oils
An additional category of “Special
Applications” included use when:
• “The generalized commodity
group’s parameters are suspected
of not adequately representing the
thermal expansion properties of
the liquid.”
• “A precise thermal expansion
coefficient can be determined by
experiment.”
While there are several sets of coef-
ficients to account for thermal expansion,
depending upon the liquid’s classification
and density at 60°F, there is only one set
of coefficients to account for compress-
ibility for all fluids, regardless of classifica-
tion. While this generalization may have
been adequate for the original purpose of
the tables, recent work has shown that it
can introduce significant errors for fluids
that do not fall within the compressibility
ranges of the fluids used to derive the
original correlations.
To explicitly examine potential limita-
tions of the API VCF method, the densities
of four of the oils used in TUV SUD NEL’s
flow measurement facilities were mea-
sured at temperatures between 10°C and
75°C, at pressures from 1 to 101 bar(a)
and the results compared with calculated
values. For each oil, the calculations were
done by treating it as a crude oil — a
refined product and a special fluid in turn.
For all four oils, the trends are broadly
similar. At the reference temperature
of 15°C, all three methods produce
good results for the four oils, and when
12 | January 2019
calculated as a special fluid, the results
are good across the temperature range,
as would be expected since the user-
defined thermal expansion coefficients
have been derived from the experi-
mental data. However, when treated
as either a generalized refined product
or a generalized crude oil, all four oils
display significant errors as the tem-
perature is changed from the refer-
ence value of 15°C, with errors of up
to -0.70 percent.
For all four oils, the smallest errors are
obtained when they are calculated as a
special fluid, because this essentially
removes the temperature-dependent
errors generated when treating them
as generalized crude oils or general-
ized refined products. However, all four
oils show the same trend of monotonic
increases in errors with pressure, regard-
less of the calculation method used, with
errors ranging from -0.6 to 0.2 percent.
The TUV SUD NEL EPAT facility uses a
volume-based device as its flow rate refer-
ence system, but is normally used to cali-
brate Coriolis flowmeters, which measure
mass flow rates. Accurate knowledge of
the density of the fluid passing through the
reference measurement system and the
device being calibrated is therefore essen-
tial. In view of the potential errors, use of
generic expansion coefficients would not
be acceptable for this application.
As TUV SUD NEL is able to measure
the density of the fluids used in its flow
measurement facilities with an uncer-
tainty of 0.025 percent across the tem-
perature range from 10°C to 90°C, at
pressures up to 90 bar(a), an alternative
approach is possible. For each fluid, the
experimental data are fitted to an equa-
tion that enables the density to be cal-
culated at any temperature and pressure
with an overall uncertainty (combining the
uncertainty of the experimental data and
the fitting process) of 0.04 percent. For
EPAT, for example, this allows the facility
to meet its overall uncertainty of 0.08
percent for mass flow rate, as the volu-
metric reference system has an uncer-
tainty of 0.03 percent.
Unfortunately, due to the large amount
of data required to optimize the coefficients
for the form of equation used by TUV
SUD NEL, this approach is not ideal as a
general replacement for the use of VCFs.
For applications where mass flow rates
are required, the use of suitably calibrat-
ed Coriolis flowmeters would avoid this
problem; however, correct calibration of
the Coriolis flowmeter is essential. If the
meter is calibrated against a volumetric
reference system using VCFs, errors in
excess of 0.2 percent could still occur.
For a field producing 50,000 barrels of
oil per day (and an assumed oil price
of $70 a barrel), this would equate to a
potential financial exposure of £2 million
per annum.
Although the use of Coriolis flowmeters
will provide a good solution in many situa-
tions, for some applications, knowledge of
the density of a fluid and its variation with
temperature and pressure is essential.
To ensure the lowest financial exposure,
direct measurement of fluid density or
the use of a suitable equation with opti-
mized coefficients should be considered.
Traceable calibration of the density mea-
surement device and validation of the
equation form and its coefficients are
also vital.
Conclusion
Although it is often overlooked, knowledge
of the density of a fluid and its variation
with temperature and pressure is vital for
many flow measurement applications. As
such, the determination and use of den-
sity data should be accorded the same
care and attention that is given to flow
measurement. FC
Norman Glen is a service
leader for densitometers
and physical properties of
fluids at TUV SUD NEL,
a provider of technical consultancy,
research, testing and program man-
agement services. Part of the TÜV SÜD
Group, TUV SUD NEL is also a global
center of excellence for flow measure-
ment and fluid flow systems and is the
U.K.’s National Measurement Institute for
Flow Measurement.
Flow Control
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Features: Custody Transfer
API 18.2: Ensure safety while
providing better level and volume
measurement options
Automating level measurements keeps workers off tanks to ensure
their safety while improving quality, consistency and accuracy of
custody transfer measurements.
By Tom Wienke, Rosemount Level Products at Emerson Automation Solutions
W
ith the growth of unconven-
tional oil and gas production
in recent years, the number of
producing sites has grown along with the
geography they cover. In locations where
there is no pipeline infrastructure, trucks
are dispatched regularly to gather the oil,
while other trucks gather water so it can
be taken to a disposal facility. Even in
cases in which pipeline infrastructure is
available, producers often use trucks as a
backup so production can be maintained
when the custody transfer equipment or
the pipeline is taken out of service for
routine maintenance.
When oil is transferred from storage
tanks to a truck, this is viewed as a custody
transfer transaction with key stakeholders.
The truck driver represents the buyer and
needs to ensure the quality and quantity
of product purchased. The oil producer
needs to ensure precise payment for the
amount of oil transferred, and the land-
owners need to have confidence they are
receiving a correct royalty payment.
With this in mind, the obvious solution
is to use sophisticated measurement
technology and practices that provide
appropriately accurate measurements.
While sophisticated equipment and tech-
14 | January 2019
niques have been widely used for keeping
track of inventory in this industry, until
recently, only manual methods have
been used for smaller-volume transfers.
These methods are defined in API 18.1:
Measurement Procedures for Crude Oil
Gathered from Small Tanks by Truck. This
standard has been in place for years and
has been widely recognized as the accepted
method for this type of custody transfer.
The basic steps involved are:
Step 1: The truck driver climbs to the top
of the tank and opens a thief hatch. A
tape measure is lowered into the tank to
determine the oil level. This first measure-
ment is called the opening gauge and
establishes the baseline measurement.
Step 2: The next step is to lower in a
temperature sensor to read the oil
temperature, which is used to support
a density calculation. A temperature
reading should be taken at three depths
due to stratification, with the three read-
ings averaged.
Figure 1. Any level-measuring technology
must detect and measure an oil/water
Step 3: A collector is dropped in to cap- interface in the tank.
ture a sample. Specific gravity can be All images courtesy of Emerson
measured using a hydrometer. Some of Automation Solutions
Flow Control

Positive displacement API MPMS 5.2
Turbine API MPMS 5.3
Coriolis API MPMS 5.6
Ultrasonic API MPMS 5.8
Orifice API MPMS 14.3
Differential pressure API MPMS 22.2
LACT systems API MPMS 6.1
Table 1. API standards covering speciic
lowmeter technologies
the sample goes into a centrifuge for the
“grind out” to determine how much water
and solid material is mixed in. The mea-
surements from this sample are applied
to the entire lot.
Step 4: At this point, if the truck driver
is satisfied with the quality, the oil can
be pumped into the truck. When the
transfer is over, the driver takes a sec-
ond level measurement (closing gauge)
with the tape to calculate the volume
transferred.
All these steps are accomplished from
the top of the tank, which presents a
variety of safety concerns. Aside from
the potential for the driver to fall off the
tank, opening the hatch can also release a
plume of hydrocarbon vapor, which could
potentially include hydrogen sulfide. A
number of fatalities have occurred when
workers were asphyxiated by the sudden
vapor plume. These fatalities prompted
the Occupational Safety and Health
Administration (OSHA) to issue a safety
alert, advising of the risks incurred when
work is performed on top of these tanks.
While workers can be trained and provid-
ed with personal protective equipment to
reduce risk, the best way to protect them
is to keep them off the tanks entirely.
A deep concern for the safety of work-
ers prompted the industry to develop and
adopt a new standard: API 18.2 Custody
Transfer of Crude Oil from Lease Tanks
Using Alternative Measurement Methods.
“Alternative” in this context means per-
forming required measurements without
requiring anyone to climb the tank to
open the thief hatch.
www.flowcontrolnetwork.com
Figure 2. A GWR transmitter, such as the
Rosemount 3308 from Emerson Automation
Solutions, works well in oil storage tank
applications.
The standard allows for multiple
approaches, including the use of a
flowmeter. A number of flow tech-
nologies are treated by the American
Petroleum Institute (API) in greater detail
in other chapters (see Table 1).
Aside from concerns with safety,
there is also the question of accuracy
when making a level measurement.
When level measurements are per-
formed manually, they depend on the
fastidiousness of the individual and
are subject to error. This is particularly
critical when reading the tape measure.
The standard for manual tank gauging
(API 18.1) requires three successive
readings to be in agreement within
0.25 inches. While that may be pos-
sible under ideal conditions, it is seldom
achieved in practice.
Operating under API 18.2
The same data should be gathered under
both 18.1 and 18.2, but the difference is
how and where measurements are made.
There are numerous top-down level mea-
surement technologies available, but some
are better suited than others. Because
there is always potential for inadequate
oil and water separation, operators should
choose a level technology able to deter-
mine an oil-water interface. While well sites
will have a separator to isolate water from
oil, the efficiency of the process can be
improved, as discussed later.
When the separation process is incom-
plete, oil and water go where they
shouldn’t. A layer of oil accumulates in the
water tank, introducing safety risks and
product loss as it is hauled away for dis-
posal. Conversely, water can accumulate
in the oil tank, which degrades the quality
of the product. Two level technologies
(see Figure 1) can measure the oil-water
interface together with the surface level:
magnetostrictive and guided-wave radar
(GWR). Both can provide the necessary
precision to satisfy 18.2 and are unaf-
fected by cold, rain or any other distrac-
tions to a human operator.
Magnetostrictive level measurement
instruments use floats that move on a
rod extending down to the bottom of
the tank. The bottom float is weighted
so it sinks in oil but floats in water,
whereas the upper float always remains
at the top of the oil. The sensing mech-
anism can determine the position of
both floats. This approach works well if
there is no gooey buildup on the rod so
the floats can move freely. When there
is a distinct interface, this technology
also can provide a reliable indication for
both overall level and interface level.
However, when an emulsion forms and
causes an ambiguous oil and water
separation, magnetostrictive technol-
ogies will incorrectly report a distinct
interface. The interface float will always
come to rest somewhere, regardless
whether there is good product separation
January 2019 | 15
 Solids and gooey tar-like materials are common
with crude oil, and they can coat the walls of the
tank and the probe of a level instrument.
or not. This provides a false sense of
certainty that the true location of the
interface is known.
Solids and gooey tar-like materials are
common with crude oil, and they can
coat the walls of the tank and the probe
of a level instrument. With a magneto-
strictive instrument, the float (or both
floats) can become partially or com-
pletely glued in place, so they do not
move freely or do not move at all in worst
cases. This has a major detrimental
effect on the accuracy of the measure-
ment, and an operator will not be able
to tell what’s happening beyond readings
freezing. The more insidious problem is
a loss of accuracy if the float can move
partially but drags, reducing repeatabil-
ity. This is not as easy to recognize from
the readings.
A GWR level instrument has a transmit-
ter (see Figure 2) mounted on top of the
tank, with a probe hanging down to the
bottom. The probe serves as a wave guide
to carry the radar pulse down to the sur-
face of the liquid. It can measure the dis-
tance far more accurately and with better
repeatability than a human taking manual
tape readings. When water sits below the
oil, some of the microwaves pass through
the oil so that an additional reflection is
made from the interface between the oil
and water. There are no moving parts,
so the instrument is tolerant of buildup
on the probe.
In general, it is unnecessary to clean
a GWR probe. However, the device does
have the capability to alert an operator
if buildup is affecting the reliability of the
measurement. The nature of the echo
created by a dirty probe (see Figure 3)
is different than a clean probe. The dif-
ference can be quantified as a variable
designated signal quality. Should the
signal quality ever drop below a critical
level, operators can be warned of the
problem so they can take appropriate
action. When the alert is triggered, online
16 | January 2019
help will give the operator instructions on
how to remedy the problem.
As mentioned earlier, the key opera-
tional differences between magnetostric-
tive and GWR hinge on how they deal
with the oil-water interface. If the two
layers are distinct, either can provide a
clear measurement. However, where the
separation is indistinct, the lower mag-
netostrictive float will still come to rest
where the density change is sufficient
to cause buoyancy, so it will indicate
an interface whether one exists or not.
When a GWR transmitter is used, if no
distinct interface is present, it will not
indicate one.
Figure 3. When the echo loses its clarity,
material buildup on the probe is usually
the problem.
While the magnetostrictive device
drives an incorrect reading under this
condition, the GWR provides useful
information. The conditions leading to a
loss of interface can result from push-
ing too much oil through the separator
without sufficient residence time. This
can drive excessive water carryover to
the oil storage tank, making it effectively
a secondary separator. This inefficiency
can be prevented by also using a GWR
transmitter in the separator and using
this valuable feedback from the GWR
transmitter to identify a loss of interface.
Should this occur, the flow through the
separator can be throttled back until the
interface is restored.
Other elements of
custody transfer
Using automated level measurement
takes care of the beginning and end-
ing level readings, but referring back
to the list of tasks addressed earlier,
there are other necessary measure-
ments that may now be accomplished
without climbing the tank, and the fol-
lowing are some examples.
Temperature measurements still need
to be taken, but these can be done in
the pipe between the tank and truck,
rather than in the tank. In fact, the ability
to take a continuous temperature read-
ing during the product transfer allows for
the temperature to be averaged over the
entire transfer. Using this method pro-
vides a temperature value that is much
more representative of the overall product
transferred and therefore contributes to
better transfer accuracy.
Samples still need to go through the
grind-out process and then a check with
a hydrometer. These samples can be cap-
tured easily and safely using a small valve,
which can be opened manually during the
transfer process.
The sample collection valve and tem-
perature sensor can be built into a short
Flow Control
Figure 4.
Recognizing when
the interface is
indistinct can help
an operator avoid
sending out mixed
product streams
containing a high
percentage of
water in crude oil.
pipe section of the same diameter as
the transfer pipe. Usually these lines use
cam-lock fittings, so it is a simple mat-
ter to create a short section that can be
inserted wherever practical.
Few tanks, if any, are built with the
kind of precision equaling the capability
of a level transmitter. In other words,
some sections of the wall are probably
a little flat in spots, so a tank will vary
at different levels. Consequently, tank
strapping tables can improve the accu-
racy of a transferred volume determina-
tion since the change in level is used to
determine volume.
For example, in a given tank, the
amount of oil necessary to cause a
24-inch change in level near the top of
the tank can be a measurably differ-
ent volume than the same level change
near the bottom due to tank bulging
and irregularities in the tank geometry.
When tanks are commissioned for this
application, great care is taken to cre-
ate a lookup table to correlate a level
measurement with the actual volume
corresponding to that level. These tables
are derived using a precise flowmeter
combined with an accurate level mea-
surement device.
www.flowcontrolnetwork.com
Is using a level transmitter
accurate enough for
custody transfer?
When API 18.2 was drafted, the objective
was to facilitate product transfer with
the same or better accuracy than using
the manual methods defined in API
18.1. Remember that API 18.1 required
three consecutive manual readings to
be in agreement within 0.25 inches.
Fortunately, the committee recognized
the industry has already deployed thou-
sands of level transmitters in their fields
with accuracies of ±0.125 inches, thus
providing for much better accuracy than
manual methods.
These devices are specified by their
manufacturers to be highly accurate, but
is it possible to prove accuracy in practice
and maintain accuracy over time?
GWR technology works by measuring
the time of flight for a pulse to travel from
the electronics down the probe and back
again. As such, the components affect-
ing the accuracy of this time travel are
contained within the electronics in the
head and not the probe. This makes it
possible to routinely remove the head and
test it using a NIST-traceable calibration
box. Such a device simulates distance
electrically using coaxial cables of known
lengths. Up to five different lengths can
be used to verify the transmitter over a
broad operating range, and a report can
be generated to provide a permanent
record of device compliance.
Working together, these elements can
produce a higher level of accuracy while
avoiding potentially lethal safety con-
cerns. API 18.2 shows how users can
put these techniques to work to produce
the desired results in a safe and repeat-
able manner with minimal requirements
for on-site labor. FC
Tom Wienke is the level
business development
director at Emerson
Automation Solutions.
He has a bachelor’s degree in mechani-
cal engineering from the University of
Minnesota. Wienke has been employed
with Emerson for the past 27 years and
has experience with operations, custom-
er support, product management and
marketing. Based in Minneapolis, he
currently leads an eight-member team
supporting Emerson’s level business
across North America.
January 2019 | 17
Features: Remote Monitoring

Connected and monitored assets

improve safety and efficiency
IIoT brings new possibilities to the plant floor for personnel and
equipment safety, asset health and time efficiencies.
By Alex Desselle, Fluke Accelix

W
hile the term Internet of Things By connecting the digital and physical
(IoT) has been around for a worlds, information exchange can be
while, the concept of the improved and elevated within industrial
Industrial Internet of Things (IIoT) is newer. maintenance applications. In this context,
Only during the last five years have more “digital” includes smart devices, comput-
developments occurred in the industri- ers and software, while the “physical”
al world; however, IIoT can be applied world encompasses plant assets and
across many applications and industries.
Recently, the maintenance and reliability
(M&R) sector has begun to take advan-
tage of these technologies.

Monitoring with wireless sensors allows

technicians and other personnel to
remain a safe distance from equipment
in operation.
All images courtesy of Fluke Accelix

18 | January 2019 Flow Control

testing and monitoring hardware. IIoT
helps plants and facilities increase visibil-
ity into machine performance and health,
inefficiency in processes and potential
savings. It offers other benefits, including
personnel and asset safety.
Different industries use the power of
IIoT in diverse ways, such as:
• M&R teams use vibration analysis,
infrared sensors, ultrasound and
power monitoring, among other tech-
nologies, to determine when condi-
tional changes occur. They use this
data to schedule maintenance before
downtime occurs.
• With fully connected IIoT devices, plant
and maintenance managers, techni-
cians and the entire plant have access
to data in real time and turn data into
actionable methods to not only prevent
failures but also predict them.
• Remote monitoring technologies keep
personnel away from dangerous rotat-
ing assets and allow them to stay
outside arc flash zones.
Improved personnel and
asset safety
In industrial plants and other facilities,
safety is of paramount concern. Many
assets may present dangers if person-
nel must be in close proximity to take
measurements. Some of these include:
• Rotating assets, such as pumps, fans,
blowers and motors
• Hot assets, such as furnaces, ovens,
heat exchangers, process piping and
large motors
• Electrical panels, from which arc flash
can occur
Monitoring with wireless sensors — made
easier and more affordable with IIoT —
allows technicians and other personnel to
remain a safe distance from equipment in
operation. They receive alarms on their
smart devices if power fluctuates or drops
(power monitoring), vibrations exceed
conditional norms (vibration monitoring),
a hazardous gas leak begins (ultrasound)
or temperatures move outside safe
parameters (thermal/infrared sensors).
Personnel receive the information
needed to make informed decisions.
www.flowcontrolnetwork.com
One action could be deciding that the
abnormality is not severe enough for
intervention. Another may be scheduling
downtime to make a repair or replace a
part. Regardless of the action taken, M&R
teams have the knowledge and control
to choose when intervention is required,
preventing unscheduled downtime and
increasing the proper operation of assets.
Proper operation not only ensures
asset health but also prevents other
personnel risks. Failing equipment can
cause catastrophic damage to facilities
and personnel who may be nearby when
the failure occurs. Maintaining appropri-
ate operation mitigates personnel and
property hazards as well.
Maintained asset health
When applied to maintaining asset health,
IIoT helps M&R teams break new ground.
M&R systems are not an all-or-nothing
implementation. Pieces and parts of a
system may be added to the technology
lineup at different times. Some measure-
ments may be gathered on preventive
routes with handheld devices. Other
measurements can be taken by wireless
sensors and still others by tools already
installed on the asset. The ability to use
IIoT technology to aggregate data from
different measurement devices is instru-
mental to the often-small steps that many
M&R teams must take as they begin the
reliability journey.
The addition of wireless sensors can
be a first step from preventive mainte-
nance to predictive or condition-based
strategies by taking measurements that
are sent to the cloud. Some technologies
that can provide early warning of immi-
nent problems include thermal imaging
sensors, vibration sensors, power moni-
toring and ultrasound.
Increased efficiency and
time savings
Reactive and preventive M&R activities
are time- and labor-intensive. Emergency
repairs and ordering parts take time and
personnel away from activities that help
prevent downtime. This can become a
circular problem as preventive activities
and time-based tasks are missed and
technicians carry out reactive work to
get assets back to normal operation.
As a result, more unplanned failures
may occur.
Preventive and time-based tasks, which
are required in many facilities and plants
and are legitimate maintenance strate-
gies, require dedicated staff to perform
them. Among the many reasons that M&R
teams should begin to limit this type of
work include:
• About 80 percent of assets examined
during time-based routes are healthy
and operating normally. Time is wasted
monitoring healthy equipment.
• Personnel must be in close proximity
to assets, increasing the risk of inju-
ries or accidents.
• Compiling data from these activities
may be error-prone and spotty.
Implementing remote, wireless moni-
toring helps teams screen equipment in
real time. This allows the M&R team to
identify any assets that are experienc-
ing problems and focus their activities
on those assets.
Connected reliability
Ultimately, IIoT allows for connected reli-
ability, which removes the major barriers
that prevent implementing IIoT and often
confound predictive maintenance initia-
tives. These barriers include:
• Missing or inaccessible data and reli-
ance on scheduled routes
• Lack of connectivity between assets,
management systems and M&R teams
• Limited access to relevant data for
timely, informed decisions on the
plant floor
To move past reactive strategies and
manual data entry, facilities need con-
nected reliability — a framework to
connect assets, systems and people.
Connected reliability gives teams a cus-
tomizable way to make a quantum leap to
a more reliability-focused reality. A con-
nected reliability framework must consist
of three essentials:
• Comprehensive data collection
• End-to-end connectivity
• Empowered teams
January 2019 | 19
 The use of remote, wireless sensors is
simple and allows the team to view real-time
data and receive alarms if assets experience
conditional changes.

analysis needed by those charged with

assuring asset health so that they suc-
cessfully meet their goal: equipment reli-
ability. Providing continuous, actionable
data to the M&R team is the final and
most important piece of connected reli-
ability. Teams will have access to the data
they need to work safely and efficiently
to maintain asset health. FC

Alex Desselle is a product

M&R teams must be able to use all data
types and sources so they can use IIoT
wherever they may be in the reliability
journey. Whether using handheld tools, a
wireless sensor, supervisory control and
data acquisition (SCADA) or any other
condition/process data, this multisource
information must be aggregated and
stored for future study and analysis. This
stored data must function in lock-step
with an enterprise asset management or
computerized maintenance management
software system. With this integration in
place, data can be available to the right
people at the right time to improve safety,
efficiency and asset health.
The ultimate goal of connected reli-
ability is full-time access to the data and
application specialist with
Fluke Digital Systems and
Accelix. With more than
30 years of experience, Desselle has been
a lead field engineer, product manager and
subject-matter expert in the oil and gas,
chemical and manufacturing industries. He
may be reached at alex.desselle@fluke.
com. For more information, visit fluke.com.

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Case study:
Ultrasonic flow metering
improves energy efficiency
To meet environmental goals, a university upgrades
its HVAC monitoring system.
By Izzy Rivera, FLEXIM, and Jack Sine
A
major Mid-Atlantic university,
founded in the late 19th century,
currently has more than 60 major
buildings on 84 acres. It generates its
own steam for heating and operates
five chilled water plants that distribute
throughout the university. The university’s
energy conservation and efficiency man-
ager recalls the long but rewarding journey
to becoming a leading green campus.
“When I first came on board, energy
usage was a concern because it was a
major operating expense that we wanted
to keep under control,” he said. “Back
then, that meant monitoring the flow of
heated and chilled water with only four
www.flowcontrolnetwork.com
alacatr/iStock
turbine flowmeters. We took that data designed to monitor fluids that were free
and used it to calculate BTU usage for of any contamination,” he said. “City
our chilled, hot and potable water.” water, as potable as it is, always con-
The university had a basic energy man- tains particulates, which are harmless
agement system, but the turbine meters to humans, but tend to collect on the
did not communicate with it, and flow vanes of turbine meters. At that time, with
data had to be entered manually. only four meters, it was only a modest
“The turbine meters served our needs inconvenience, but became more impor-
at the time, but needed frequent cali- tant as we started upgrading our energy
bration and cleaning because they were management capability.”
It was clear to the university’s environmental
team that extensive flow measurement was key
to maximizing efficiency.
January 2019 | 21
Environmental team
When the green energy movement began
gaining media attention, the university’s
management also decided that it would
take a leading position to become a
green campus. One of its highest pri-
orities was the need for more efficient
energy management.
The university was in the process of
developing its environmental issues proj-
ect team to recommend steps on how to
fulfill its responsibility to protect the envi-
ronment. The team also had the charge
to increase environmental awareness on
campus. Student environmental activism
has since grown into a major presence
on the campus.
“We were determined to create the
greenest of the green campuses,” said
the university’s energy outreach program
leader. “While we recognized the biggest
potential source of savings was hot and
cold water energy usage, we were ada-
mant not to overlook even the smallest
source that could contribute to the green-
ing of our campuses. However, our first
major focus was energy use.”
A question of metering flow
It was clear to the university’s environ-
mental team that extensive flow measure-
ment was key to maximizing efficiency.
As facility management began to focus
on higher energy efficiency, the heads of
the school began to look at minimizing
the university’s carbon footprint.
“We knew early on that we would need
a lot more flow measurement than we
already had,” said the university’s energy
conservation and efficiency manager. “I
wasn’t happy with the turbine meters I
had inherited because of the time-con-
suming cleaning and recalibration. We
investigated every flow metering technol-
ogy we could identify, everything we could
think of – vortex shedding, displacement,
Coriolis, mags and others, but they all
had the same problem as the turbine
meter – they all made direct contact with
the fluid whose flow they were measuring
and would need frequent cleaning and
calibration.”
The team’s research led them to ultra-
sonic flow measurement.
22 | January 2019
The university now has more than 60 ultrasonic
meters monitoring its HVAC flow and temperature
and reporting to its dashboard/BAS system.
“Ultrasonic flow measurement had
been around for a while,” he said. “Some
of it was intrusive, but emerging meter
technology that clamped onto the outside
of a pipe and measured flow by send-
ing ultrasonic pulses through the pipe
wall was intriguing. We did research on
what was available and decided to try
one brand of clamp-on meter that looked
like it could meet our needs, but it didn’t.”
The wrong ultrasonic
“They chose an ultrasonic meter that
didn’t fit their application well,” said Travis
Teeter, an industrial sales engineer for
Flow-Tech, one of the university’s major
suppliers for measurement technologies.
“The meters were big and bulky, and the
only way they could install them was to
build a large box around the pipe. They
also had a lot of maintenance problems
because they constantly had to reapply
coupling grease to the meters’ transpon-
ders because the grease would migrate,
gradually moving the transponders, and
eventually degenerating the signal.”
The university team recognized that this
particular ultrasonic meter did not fit its
needs, but the team was sure the technol-
ogy itself was what they were looking for.
A more practical
ultrasonic solution
The university team then brought Flow-
Tech into the search — a supplier that
has helped solve measurement problems
in the past, but not yet for its flow mea-
surement solutions.
“At that time, we had taken on a manu-
facturer of ultrasonic meters who focused
on large-volume applications,” said Teeter,
who was sure that FLEXIM Americas was
a good fit for this application; however,
the university’s team was wary after its
first experience with ultrasonics.
“Not only was the contact gel a prob-
lem, we needed meters that would com-
municate with our energy management
system,” said the university’s energy
conservation and efficiency manager.
“The previous meters did to an extent,
but not as effectively as we wanted. We
had recently upgraded to an Apogee
system that has been excellent at ana-
lyzing energy data, so we needed flow-
meters that could provide the immedi-
ate data it needed to help us maximize
efficiency.”
How ultrasonic
metering works
“The technique most ultrasonic flow
meters use is called transit-time differ-
ence,” said Teeter. “It exploits the fact
that the transmission speed of an ultra-
sonic signal depends on the flow veloc-
ity of the carrier medium, kind of like a
swimmer swimming against the current.
The signal moves slower against the flow
than with it.
“When taking a measurement, the
meter sends ultrasonic pulses through
the medium, one in the flow direction
and one against it. The transducers alter-
nate as emitters and receivers. The transit
time of the signal going with the flow is
shorter than the one going against. The
meter measures transit-time difference
and determines the average flow velocity
of the medium. Since ultrasonic signals
propagate in solids, the meter can be
mounted directly on the pipe and mea-
sure flow noninvasively, eliminating any
need to cut the pipe.”
What the university team said about
gel migration was true, and it was true
with the two ultrasonic meters they origi-
nally ordered.
“Those original meters relied on a gel
to make acoustic contact between the
meters’ transducers and the exterior of
the pipes they monitored,” said Teeter.
“The heat from a hot water pipe would
cause the gel to migrate from the con-
tact area and give faulty temperature
and flow measurements. The gels have
a limited temperature tolerance. Also,
high temperatures accelerate the aging
Flow Control
of the transducer’s piezzo elements and
reduce their operating life.
“That’s why FLEXIM developed per-
manent contact pads to replace gels for
most high temperature applications up
to 400°F. For higher temperatures, we
developed and patented our WaveInjector
transducer mounting fixture. It permits
the transducers to be mounted at a safe
distance from the pipe while still main-
taining accurate readings. It enables a
set of standard transducers to operate
accurately at temperatures ranges from
minus 160°F to plus 1,100°F.”
The university now has more than 60
ultrasonic meters monitoring its HVAC
flow and temperature and reporting to
its dashboard/BAS system. It also added
more new meters for domestic water and
continues to expand each building. Its
future plans call for adding more analyt-
ics on the data for more efficiency.
The success of the
greening program
The new metering and upgraded Apogee
system and dashboard were the major
first steps in kicking off the greening of
the university’s campus,” said the univer-
sity’s energy outreach leader. “But they
were far from the last.”
While the team was adding the HVAC
monitoring system, the university was also
addressing the other aspects of green-
ing the entire campus, such as involving
students in the environmental projects
and increasing environmental awareness
on campus.
Recently, the Association for the
Advancement of Sustainability in Higher
Education (AASHE) awarded the univer-
sity a gold rating on their STARS scale for
sustainability. In the same year, the uni-
versity’s School of International Service
building received the Leadership in Energy
and Environmental Design (LEED) Gold
certification for its 70,000-square-foot
building that is renowned for sustainable
design and “cradle-to-cradle” philosophy.
The university was also ranked number 2
in the Sierra Club’s list of the Top 10
Greenest Colleges. FC
Izzy Rivera is the director of techni-
cal operations/product manager for
FLEXIM Americas Corporation. He has
been involved with the development
of ultrasonic flow measurement for 37
years and is a co-founder of FLEXIM
Americas, a subsidiary of FLEXIM GmbH.
He can be reached at 631-492-2300.
Jack Sine is a freelance writer specializing
in HVAC, green building and IAQ issues.
He can be reached at jack.sine@verizon.
net or 845-831-6578.

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www.flowcontrolnetwork.com January 2019 | 23

Best Practices & Applications
Performing a
storage tank risk
assessment
Petroleum storage tanks should be ready
for updates to API 2350.
By Dean Mallon, Endress+Hauser
A
PI 2350 gives tank owners and
operators specific guidance on
how to prevent tank overfills. The
standard has been around for years, with
the fourth edition published in 2012, and
the fifth edition is expected to be released
mid-2019.
The following describes what’s expected
in the new standard and what a plant
owner or operator should do to comply.
About API 2350
The API 2350 standard is intended to
provide tank operators with the best
practices for preventing overfill events
in petroleum storage tanks. The storage
of any large amount of fuel, crude oil and
Figure 1. Facility ire caused by an overlowing
storage tank could result in hazardous
conditions. Courtesy of Endress+Hauser
24 | January 2019
other hazardous liquid creates risk and
potential danger at a facility if not properly
operated, maintained and designed.
What makes a tank overfill uniquely
hazardous is that it can generate a deadly
vapor cloud, which can flow out far past
secondary containment, resulting in a
detonation and hazardous conditions for
nearby communities. One example that
had a major influence on API 2350 is
the Buncefield fire in 2005. It led to the
current emphasis on overfill prevention
in petroleum storage tanks.
It’s important to note at this point that
API 2350 is not a regulation that plant
owners must conform to, but is instead
a recommended standard. But organiza-
tions that adopt the processes described
in API 2350 will benefit from control of process. Efficiency may improve because
hazards — resulting in reduced exposure implementing API 2350 often results in
to risk, incidents and accidents — and an expansion of usable tank space.
lower insurance premiums and operat-
ing expenses. Primary points covered
The new practices urged by API can by API 2350
also improve normal operation and effi- API 2350 contains a series of recommended
ciency. Improved operations are the result practices and procedures, including:
of specific, clear and actionable proce- • Implement an overfill prevention
dures that are understandable and acces- process (OPP).
sible to operations personnel. Removing • Apply preventive maintenance prac-
uncertainty at facilities creates less varia- tices to overfill prevention system
tion in operations, creating an improved and equipment.
Flow Control

• Develop written procedures for
operating under normal, abnor-
mal, startup and shutdown condi-
tions — as well as communications
between the supply and receiving
companies.
• Define initializing operating param-
eters for each tank. This covers
equipment categories, levels of
concern, response times and alarm
procedures.
• Implement and maintain a risk assess-
ment system.
www.flowcontrolnetwork.com
Space does not permit a detailed
analysis of every provision of API 2350.
Conforming to API 2350 does require a
detailed risk assessment of storage tanks
and comparison to the standard’s recom-
mendations. The following is an example
of a high-level risk assessment.
Risk assessment and
management
Reducing the risk of an overfill is the main
objective of API 2350. Risk assessment
is knowing a company’s level of risk, and
TommL/iStock
risk management is acting to reduce it.
Risk assessment determines the likeli-
hood and consequence of harmful events,
but simply knowing the risk level does not
help unless those risks can be reduced
to an acceptable level, which requires
risk management. Proper application of
this methodology reduces risk by recom-
mending corrective actions.
Effective risk management assumes
that the risk assessment uses a valid
approach that is timely, effective, audit-
able, explainable and practical. To be
January 2019 | 25
Figure 2. API 2350 deines a properly instrumented and engineered tank. This tank, for example,
has an independent overill protection system, a high-high point level switch and an emergency
shutdown valve. Courtesy of Endress+Hauser
effective, it is essential to formulate an
assessment strategy that ranks and pri-
oritizes risks.
API 2350 specifically states that a risk
assessment must be implemented and
maintained, but it does not specify how to
do this because risk assessment methods
and techniques often vary for each plant
or facility.
The risk analysis process
incorporates the results
of data collection,
organization, analysis
and assessment.
Different levels of risk are associated
with each tank because the filling rates
are different, sensors have differing reli-
ability and other factors that can influence
the tanks (see Figure 2). The likelihood
of an overfill event requires tank-specific
information such as filling rate, installed
instrumentation and other data.
26 | January 2019
There are many ways to perform risk
assessments, and each has its pros
and cons. Moreover, each company
must develop individualized styles and
methodologies for executing risk assess-
ments. The risk assessment procedures
described in the following section are
from the updated Endress+Hauser Risk
Analysis Tool. This tool supports and aids
an organization’s dual objectives of com-
pliance with best industry practices and
the most effective elimination of risk.
Performing a risk
assessment
The risk analysis process incorporates the
results of data collection, organization,
analysis and assessment. For example,
specific tank information such as filling
rate, previous spills/near misses, operator
reliability, implementation of automatic
overfill prevention system (AOPS) and
gauging system reliability can be compiled
and included in the analyzer’s database.
In addition to data on size and frequency
of events, the severity of various failure
modes is also included. For example, the
severity of an overfill or spill event may be
influenced by the filling rate, the hazard
associated with the liquid, proximity to
town/city, containment capabilities and
early awareness.
The first step is to appoint a team of
engineers and operators from the tank
farm or an outside agency to perform the
risk assessment. This person or team will
survey every tank in the plant and assign
a risk factor to each one.
The risk factors are arbitrary. Table 1
shows one potential scenario of numbers,
but they can be anything that is meaning-
ful to the plant.
With the risk factors in mind, the person
or team evaluates each tank according
to this procedure. The Risk Analysis Tool
Levels of contribution Metric
to a tank overfill (Score)
De minimus 0
Minor contribution to overfill .1
Ordinary or average
.3
contribution to tank overfill
Above average contributor to
.6
tank overfill
High contributor to tank
1.0
overfill
Table 1. Numeric rankings of various factors
that can lead to a potential overill
Flow Control
is separated into three pages: operations
grading sheet, likelihood grading sheet and
consequence factors grading sheet.
The ideal tank would be outfitted with
instrumentation similar to that shown in
Figure 2. The assessment person or team
may want to designate this condition as
ideal and assign risk factors if any instru-
mentation is missing. At a minimum, a
tank should have a high-high limit switch
(see Figure 3).
Figure 3. Every tank should have a high-high
limit switch, such as this one. Courtesy of
Endress+Hauser
Figure 4. Summary bar chart of risk factors for each tank. The tanks on the left have the highest risk
of an overspill. Courtesy of Endress+Hauser
www.flowcontrolnetwork.com
Step 1: A tank group is determined —
possibly the oldest group of tanks. Each
tank is then reviewed for its parameters,
operational procedures, emergency
response, operator training and all rel-
evant factors influencing risk (such as
proximity to town) prior to operating the
Risk Analysis Tool.
Step 2: A grading sheet is provided to
grade or score six areas of concern
regarding operations. As each of the six
areas receives a grade, each grade is
also weighted based on the influence or
importance of each area. The higher the
operational quality score, the less likely it
is that a risk event will result from opera-
tional failures; the severity is expected to
be less, too. If operators are well-trained,
have clear procedures, have prepared
an emergency response plan, test their
level-gauging equipment and independent
alarms and carefully plan receipts, then
the facility will on-average respond better
to risk initiators.
Step 3: The second sheet pertains to
both the likelihood and consequence
factors related to an overfill event. The
likelihood factors are dependent on tank
parameters such as the filling rate, flam-
mability of liquid stored, calibration mea-
sures and tank category. These graded
values are also weighted based on influ-
ence and importance.
Step 4: The consequence factors are
next. They are dependent on corporate
values such as preventing flammability,
protecting public perception, environmen-
tal protection and the severity due to tank
flow rate. The consequence factors are
then multiplied by a weight value.
Step 5: Once each likelihood and con-
sequence factor has been graded by per-
sonnel or a tank surveyor, a final score
is produced. Obtaining this score is the
goal of using the Risk Analysis Tool. If
the risk score is high, then there is a
high likelihood and severity for a risk
event. The tanks with the largest risk
scores pose the largest threat to a facil-
ity, and these are the tanks that should
be addressed first.
Step 6: A summary ranking sheet is cre-
ated from the various risk factors (see
Figure 4). Once each tank is submitted
into the ranking sheet, the result will be
a bar graph of the risk score for each
tank included in the risk analysis. The
tanks with the highest risk scores have
the highest bars. These high-risk tanks
are the most dangerous and most likely
tanks to experience an overfill or spill.
The final outputs of this risk analysis
spreadsheet are visual and quantitative
representations of the risk associated
with each tank within the survey. This
information empowers companies to allo-
cate funds for preventing risky events in
the most effective way possible.
Visit endressdirect.us/api for more
information. FC
Dean Mallon is the national
marketing manager for level
products at Endress+Hauser.
Previously, he was a region-
al level product business manager and a
rep owner/partner. He serves on various
industry committees, including the API
2350 4th and 5th edition working group.
January 2019 | 27
Trade Shows & Events
AHR Expo offers a range
of HVACR product solutions
with IoT capabilities
T
he International Air-Conditioning,
Heating, Refrigerating Exposition
(AHR Expo) is a leading heating,
ventilation, air conditioning and refrigera-
tion (HVACR) event. Each year, the event
consists of more than 2,100 exhibitors
and attracts more than 60,000 attendees.
The 2019 Expo, co-sponsored by the
American Society of Heating, Refrigerating
and Air Conditioning Engineers (ASHRAE)
and the Air Conditioning, Heating and
Refrigeration Institute (AHRI), is January
14-16, 2019, at the Georgia World
Congress Center in Atlanta, Georgia.
Since 1930, the show has provided a
forum for the HVACR industry where
OEMs, engineers, contractors, manu-
facturers, distributors and educators in
commercial, industrial and institutional
facilities come together to discover the
latest products, learn about new tech-
nologies and develop mutually beneficial
business relationships.
What to expect
Exhibitors display new solutions that serve
HVACR functions ranging from highly
efficient equipment and components to
28 | January 2019
Georgia World Congress Center
All images courtesy of AHR
Atlanta
EXHIBITION SCHEDULE
Mon., Jan. 14, 10 a.m.–6 p.m.
Tues., Jan. 15, 10 a.m.–6 p.m.
Wed., Jan. 16, 10 a.m. – 4 p.m.
ahrexpo.com
whole-building management systems, control and IoT technology; the Software
such as building automation and control Center, designated for HVACR-related
technologies that connect and commu- software, project and field service man-
nicate via the Internet of Things (IoT), agement and systems design; and the
and time-saving tools and instruments Indoor Air Quality Association Pavilion,
that require less time at the job site and which will showcase products related to
many additional products and solutions IAQ to member companies.
that support efficiency. HVACR products on display include:
The show features thousands of prod- • IAQ diagnostic instruments that
ucts in more than 770 categories, such guide HVAC professionals through
as heating systems, air conditioning the entire measurement process
units, refrigerating equipment, ventila- for more accurate reads and more
tors, ducts, and fans, indoor air quality timely detection of air quality issues
(IAQ)-related products, including filters, • Evacuation hose delivering a conduc-
building automation, controls, networking tance speed of 16 CFM at 1,000
and energy management systems, radiant microns, resulting in vacuum speeds
heating, hydronic systems and plumbing up to 80 times faster than standard
products, tools and instruments, software ¼-inch I.D. hoses and up to six times
for HVAC design, estimating and service/ faster than other vacuum-rated hoses
business management, and solar, geo- • Software application that supports
thermal and other renewable energy HVAC professionals via a download-
related products. able iOS and Android mobile app
that can be used to create on-site
Show floor sections customer reports and is inclusive of
There are three product sections within graphical data and airflow “grades”
the show floor: the Building Automation based on the simple input of name-
and Control (BAC) showcase, which will plate information and two static
focus on building automation, climate pressure values
Flow Control
 • Water-cooled centrifugal chiller that
supports low global warming poten-
tial (GWP) via improvements in com-
pression and integration of variable
speed technologies, specifically
designed to meet customer demand,
lower energy costs and reduce envi-
ronmental impact
• Fabric air duct system that improves
end air dispersion, designed to
replace traditional ductwork, insu-
lation, diffusers and air valves with
more even airflow that results in
better energy efficiency and low-
ered operation costs, as well as easy
installation and product maintenance
• Internet-enabled wireless thermom-
eter that uploads and stores tem-
perature readings on the cloud and
has the ability to send automatic
alerts for extreme low or high read-
ings directly to the user’s phone or
tablet, and it can store up to 12
months of data for efficiency evalu-
ations throughout the year
More products on display include:
• Actuators and valves
• Boiler water treatment
www.flowcontrolnetwork.com
• Burners
• Cooling towers
• Corrosion control equipment
• Filters
• Flow, temperature and level controls
• Flowmeters and gauges
• Heat exchangers
• Pumps, motors and drives
• Renewable energy products
• Seals and gaskets
• Sensors
• Software and analyzers
• Water treatment
Presentations
Attendees can also sit in on more than
50 exhibitor product and technology pre-
sentations. Some of these include:
• TCOD-Clean: High Purity Filtration
Selection and Design
• Marley MD Everest Counterflow
Cooling Tower
• Why is Filtration Critical for
Minimizing Legionella Growth
• The Array Boiler: High-Efficiency
Condensing Boiler with the Benefits
of Redundant Heat Exchangers
• Geothermal Heat Pumps Meet
the Future
• Reduce the Space Required for
Your Evaporative Cooling Equipment
While Saving Water and Energy
• Keeping Your Operations Flowing
– Accurate Flow Metering Without
Cutting the Pipe or Shutting Down
Your System
• The Final Evolution of Pressure
Boosting Technology
• Why Use NSF Certified
Pressure Gauges
• VFD Trends and Time Savers
• All About Oil Separators
Certifications
Advance registration and additional fees
are required to participate in review ses-
sions and exams. These certifications
include:
• NAFA Certified Air Filter Specialist
(CAFS) testing and two-hour
tutorial and NCT testing
• Commissioning Authority (CxA)
workshop and exam
• HVAC review and North American
Technician Excellence (NATE) testing
• New Construction Commissioning
and ACP exam
• ASHRAE certification exams FC
January 2019 | 29
Featured Products

Send products for consideration in this section

to mrogers@endeavorbusinessmedia.com.

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simultaneously. Built-in All wetted materials comply with FDA/USP Class VI
features include a two- and ISO 10993 and are manufactured in an ISO
level warning and alarm system, logging of sensor data 13485 certified site within an ISO 7 clean room
and remote monitoring with a smartphone app. environment.

Piping system Rotary seal

GF Piping Trelleborg
Systems’ ChlorFIT Sealing
Schedule 80 Solutions’
CORZAN CPVC Turcon Roto Glyd
(chlorinated Ring V seal is
polyvinyl chloride) engineered for
piping system machinery where
handles highly aggressive chemicals that typically cause a high pressure to velocity value is required to allow
corrosion. The pipe and fittings are extruded/molded from equipment to run at the highest possible speeds
premium-grade CPVC Corzan compound. It can operate in high pressures for an extended service life. It is
from 32°F to 200°F (0°C to 93°C) and is available in available in four cross section series for shafts in
sizes ¼ to 24 inches. Pipe joining is accomplished using diameters from 35 to 500 millimeters and for bores
solvent welding, threaded joints and full-pressure flanges. from 22 to 500 millimeters.

30 | January 2019 Flow Control

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SOLUTIONS FOR FLUID MOVEMENT, MEASUREMENT & CONTAINMENT

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AD INDEX
Advertiser Page# Advertiser Page#
Badger Meter Inc. ........................................................................... 1 O’Keefe Controls............................................................................. 9

Check-All Valve............................................................................. 20 Sika USA Inc ................................................................................ 23

Endress+Hauser Inc. ....................................................................BC Spitzer and Boyes LLC .................................................................. 20

KROHNE Inc ................................................................................... 3 VEGA Americas Inc ...................................................................... IFC

Neoperl Inc................................................................................... 23

BC = Back Cover IBC = Inside Back Cover IFC = Inside Front Cover

www.flowcontrolnetwork.com January 2019 | 31

 FEATURED
CONTENT

FlowControlNetwork.com

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@FLOWCONTROL_MAG

When purchasing and

installing a #centrifugal
#pump, the goal is to procure
Using high-efficiency pumps with properly applied
one that will operate as
reliably and efficiently as variable speed controls will warrant significant
possible while meeting energy savings for a given hydronics system.
process demands. @HIpumps
–Mark Handzel, Bell & Gossett
| ow.ly/oDLQ30mVITh

#Vibration analysis detects

issues in #fluid handling
Courtesy of United Electric Controls

systems | ow.ly/QuPT30mTvjE
WHAT'S ON FACEBOOK
A coal-fired power plant
works with a #valve
servicer to improve valve
performance and lower
costs in downtime, repairs
and replacements.
@armourvalve |
ow.ly/ObcM30mQqT1
Reducing methane
emissions from natural gas
Market update: Growing
adoption of smart #flow Developments in leak detection
address challenges to keep
#sensors in high-end methane out of the atmosphere.
application sectors such
as #oilandgas is expected bit.ly/2B3J9oy
to drive the market |
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facebook.com/flowcontrolmagazine @flowcontrol_mag linkedin.com/groups/4068011/profile

32 | January 2019
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