Trade Show Preview

EASA 2019
Page 30

Motors
& Drives
Energy-saving technologies
for pump systems

Also Inside

Nominations for
Innovation Awards

Roller bearing failure

and prevention strategies

Asset-specific apps
for plant operations

JUNE 2019 • Vol. XXIV, No. 6

www.flowcontrolnetwork.com
 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
SOLUTIONS FOR FLUID MOVEMENT, MEASUREMENT & CONTAINMENT

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GF Piping Systems

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• Derived Functions : Ratio, Difference, Sum, % Rejection,
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• Onboard Clock and Calendar for Scheduled Events
The 9950 SmartPro Transmitter takes a simple approach to
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CAST
YOUR
VOTE
Nominations are in for our annual Innovation Awards
program. Help us recognize the best-of-the-best
breakthrough solutions for the fluid handling industry.

 The deadline to vote is JUNE 30.

Cast yours now at
flowcontrolnetwork.com/innovationawards
Table of Contents | June 2019 • Vol. XXV, No. 6

Cover Series
Motors & Drives
10 Maximizing energy savings through
pump unit VFDs
By Patrick Hogg, Nidec Motor Corporation,
and Jim Sanderson, Motion Industries
Motor manufacturers offer protections to mitigate
effects of pulse width modulation so that benefits
of adding a variable frequency drive to a pump
system can be achieved.

14 Motor management:
Intelligence made easy
By Stephen Zbytowski, Eaton
10
Better motor performance and advanced monitoring
can help save energy costs, protect systems and
improve safety.

Features
16 Major causes of roller bearing failure
and prevention tools
By John Bernet, Fluke Corporation 20 23
Roller bearing reliability can be strengthened with
proactive maintenance strategies.

20 An effective IIoT entry point is through Departments

software applications
By Ron Fleissman, Emerson Automation Solutions
Purpose-built apps designed for specific assets are a
4 From the Editor
simple, cost-effective way to improve plant connectivity.
6 News & Notes
23 Case study: Cleaning with controlled
gas explosions 8 Application Corner & Quiz Corner
By Fabian Hössli, Kistler
A U.S. plant partners with an industrial cleaning company
and a blast measurement specialist for emergency
30 Trade Shows & Events
component cleaning.
31 Advertiser Index

Innovation Awards 32 FlowControlNetwork.com

26 Nominations for 2019
Read about the nominees before casting your vote at
Cover: imantsu/iStock

flowcontrolnetwork.com/innovationawards

Flow Control (ISSN #2641-6735) is published 12 times a year © Endeavor Business Media, 2019. No portion of this publica-
by Endeavor Business Media, 1 Mt. Laurel Avenue, Suite 207,
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2 | June 2019 Flow Control

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More facts about the OPTIMASS 6400: us.krohne.com/optimass-6400

 VICE PRESIDENT & GROUP PUBLISHER
MICHAEL C. CHRISTIAN
mchristian@endeavorbusinessmedia.com
EDITOR IN CHIEF
From the Editor MOLLY ROGERS
mrogers@endeavorbusinessmedia.com
CONTRIBUTING EDITORS

T
his issue, Flow Control is proud
to present the nominations for our
annual Innovation Awards program.
Read about the latest breakthrough solu-
tions in fluid handling applications on
page 26, and then be sure to go online
AMY W. RICHARDSON
motor and VFD. You’ll also find an arti-
arichardson@endeavorbusinessmedia.com
cle from Eaton’s Stephen Zbytowski who MARIE MCBURNETT
talks about motor management relays mmcburnett@endeavorbusinessmedia.com
and advanced monitoring. Also, Fluke GROUP ASSISTANT EDITOR
Corporation’s John Bernet discusses DANIEL GADDY
causes of roller bearing failure and pre- dgaddy@endeavorbusinessmedia.com

and vote at flowcontrolnetwork.com/ vention strategies. COLUMNIST

innovationawards. We will close the vot- Next, read about an effective way that DAVID W. SPITZER
ART DIRECTOR
ing on June 30 and present the honorees plants can make the jump into the inter-
RYAN CARLSON
in the October issue. net of things by using
PRODUCTION MANAGER
Good luck to all of the purpose-built apps AMANDA PORTER
nominees! and software applica- aporter@endeavorbusinessmedia.com
Last month, I had the tions for specific plant DISTRICT MANAGER
opportunity to learn assets to improve con- JAY HAAS | 281-980-5831
more about a few of nectivity, help optimize jhaas@endeavorbusinessmedia.com

these solutions at the processes and protect ACCOUNT MANAGER

Offshore Technology operations. Lastly, we ADDISON PERKINS | 205-463-1774

aperkins@endeavorbusinessmedia.com
Conference in Houston. present a case study
NATIONAL ACCOUNTS MANAGER
I enjoyed seeing familiar from Fabian Hössli
JIM SEMPLE | 908-963-3008
faces as well as mak- with Kistler. The blast jsemple@endeavorbusinessmedia.com
ing new connections. measurement special- ACCOUNT MANAGER
Thank you for taking ist partnered with an LISA WILLIMAN | 518-322-6691
the time to speak with industrial controlled lwilliman@endeavorbusinessmedia.com
me, and I look forward OTC 2019, NRG Park, Houston gas cleaning company DIGITAL BUSINESS DEVELOPMENT MANAGER
to presenting some of Courtesy of FC staff for an emergency com- MICHAEL RING | 347-365-0641
mring@endeavorbusinessmedia.com
the interesting new projects happening ponent cleaning project at a U.S. plant.
MARKETING MANAGER
offshore, as well as in other areas of the I hope you enjoy reading this issue of
NICK PHILLIPS
oil and gas industry and beyond. Flow Control and discover helpful solu-
DIGITAL OPERATIONS MANAGER
This issue’s cover focus takes a closer tions for your operations. MARY BETH ROMANO
look at motors and drives. First, an article AUDIENCE DEVELOPMENT MANAGER
co-written by Patrick Hogg with Nidec Sincerely, ANNA HICKS
Motor Corporation and Jim Sanderson SUBSCRIPTION & REPRINT REQUEST
with Motion Industries discusses motor flowcontrol@omeda.com
protections for variable frequency drives
CORPORATE TEAM
(VFDs) and maximizing energy savings Molly Rogers
CHIEF EXECUTIVE OFFICER
for pump systems. Hogg and Sanderson mrogers@endeavorbusinessmedia.com CHRIS FERRELL
provide guidelines for achieving a suc- @FlowControl_Mag CHIEF OPERATING OFFICER
cessful design and installation of the PATRICK RAINS
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 | June 2019 Flow Control

News & Notes
Company news
Orbital Gas Systems
showcases new technologies
at open house
Orbital Gas Systems, a wholly owned
energy subsidiary of CUI Global Inc.,
held a technology showcase and open
house for customers and suppliers at
its Houston facility. The 39,000-square-
foot facility supports the growth of the
upstream, midstream and downstream
product lines and services, including gas
metering, process control, telemetry, gas
sampling, environmental monitoring and
biomethane systems. More than 150
attendees, including midstream and
downstream end users and service
companies, viewed featured technolo-
gies, including GasPT analysis units, VE
Technology sampling equipment, mercury
analyzer systems, Integration modules
and biomethane solutions.
ITT acquires Rheinhütte
Pumpen Group
ITT Inc. completed the acquisition of
Rheinhütte Pumpen Group, a designer
and manufacturer of centrifugal and
axial flow pumps, from Aliaxis Group
S.A. The acquisition aligns with ITT’s
focused growth strategies in target
markets and provides the company’s
Industrial Process (IP) segment with a
complementary portfolio of pump tech-
nologies suited to corrosive, abrasive
and high-temperature environments.
The acquisition also bolsters IP’s pres-
ence in Europe through enhanced pump
engineering, manufacturing, testing and
channel-to-market capabilities.
TASI Group acquires ONICON
Measurement Solutions
TASI Group, a privately owned industrial
test, measurement, inspection and
assembly business, acquired ONICON
Measurement Solutions, which includes
the ONICON, Fox Thermal, Seametrics,
Greyline and Pulsar Process Equipment
brands. The ONICON Measurement
Solutions companies will become part
of the existing TASI Flow Group of com-
panies, which are currently comprised
6 | June 2019
of AW-Lake Company, Exact Dispensing
Systems, KEM GmbH, Litremeter,
SignalFire Wireless Telemetry, and
Vogtlin Instruments.
New CEO at Siemens
Oil & Gas
Arja Talakar was appointed CEO of Siemens
Oil & Gas. He is based in Houston, Texas,
the global headquarters for Oil & Gas and
its parent operating company, Siemens
Gas and Power. Talakar was previously
responsible for Siemens Saudi Arabia. He
began his career with Siemens in 1996
as a rotating equipment and automation
systems engineer.
TUV SUD NEL launches JIP
for oil-in-water analyzers
TUV SUD NEL launched a joint industry
project (JIP) to fill a significant knowl-
edge gap in the oil and gas industry’s
use of online oil-in-water analyzers to
help optimize oil and gas recovery. The
JIP will deliver a new set of regulatory
requirements for subsea produced water
discharges as well as guidance for the
acceptance of using online oil-in-water
analyzers for unmanned and subsea
applications. It will also create a new set
of validation criteria for the use of oil-in-
water analyzers for reporting purposes.
This will help operators optimize their
production process, maximize the effi-
ciency of oil and gas recovery and reduce
operational costs. It is intended that the
JIP’s research work will enable the exist-
ing online oil-in-water analyzer guidance
from OSPAR, BEIS and Norsk Olje & Gas
085 to be updated and improved.
Logan Industries expands
services into West Texas
Logan Industries, a hydraulic repair,
manufacturing and rental company,
expanded its land rig equipment ser-
vices capabilities into West Texas. The
new service will cover Midland, Odessa
and the surrounding 100-mile radius,
enabling Logan to offer quicker on-site
and on-call services to these remote
regions. Logan purchased a service
truck outfitted with all required tools and
spares for the most common hydraulic
troubleshooting and light repair work.
There will be a crew of three on rotation
at all times with a service manager located
in Hempstead, Texas. Jim Trullinger, ser-
vice manager, will be in charge of this
new service area.
Ecogreen Tank Monitor
introduces a savings calculator
Ecogreen Tank Monitor introduced an
interactive savings calculator to help
estimate how much money can be saved
by deploying tank monitors. The Savings
Calculator, found on the company’s web-
site, allows for the input of labor costs
of manually checking tank levels, plus
the cost of run-outs that result in idled
equipment and workers. The calculation
results in an annual savings that can be
compared to the cost of purchasing or
leasing the Ecogreen Tank Monitor. Fuel
distributors and suppliers of other liquids
can also use the Savings Calculator to
determine delivery cost savings based on
cost per delivery or cost per mile.
Smith-Cooper International
to merge with Anvil
International
Anvil International, a designer, manufac-
turer and provider of products that con-
nect and support piping systems, and
Smith-Cooper International, a global
designer and provider of pipes, valves
and fittings, have entered into a defini-
tive agreement to merge. The combined
company — majority owned by Tailwind
Capital — will be a designer, manufac-
turer and provider of products that con-
nect and support piping systems with
a portfolio of global brands including
AFCON, Anvil, Anvil EPS, Anvil-Strut,
Basic-PSA, Beck, Catawissa, Cooplok,
Cooplet, FlexHead, FPPI, Gruvlok, J.B.
Smith, North Alabama Pipe, Megawatt,
SCI, Sharpe, SPF/Anvil and SprinkFLEX.
Together, Anvil and Smith-Cooper will
offer a comprehensive product portfolio
to national, regional and local distribu-
tors across North America serving the
industrial, commercial, fire protection,
energy and mining end markets. The
transaction is expected to close in the
second quarter of 2019.
Flow Control
Awards &
Milestones
Armstrong Fluid Technology
recognized with British
pump industry award
Armstrong Fluid Technology’s Design
Envelope Tango pump was awarded the
accolade of Environmental Contribution
of the Year at the 2019 BPMA Pump
Industry Awards. Founded by the British
Pump Manufacturers Association (BPMA)
in 2000, the Pump Industry Awards
program celebrates the achievements
of pump companies and individuals.
Judges commented on Tango pump’s
levels of efficiency and innovative
Parallel Sensorless Pump Control. Using
advanced design, embedded intelligence
and connectivity, as well as motor effi-
ciency exceeding the IE4 standard, Tango
pumps deliver energy savings.
NETZSCH celebrates 50th
anniversary of North
American operations Upcoming events
NETZSCH Pumps North America LLC is cel-
ebrating its 50th anniversary. As a mid-sized, Sensors Expo
family-owned German company, NETZSCH June 25–27
San Jose, California
manufactures machinery and instrumen-
sensorsexpo.com
tation with worldwide production, sales
and service. The global company began its EASA
North America operations as a one-person June 30–July 2
office 50 years ago and has since grown Las Vegas
to more than 180 employees for its three easa.com
North American business units, Analyzing
& Testing; Grinding & Dispersing; and ISA Energy & Water
Pumps & Systems. NETZSCH marked the Automation Conference
milestone year with a gala celebration on Aug. 7–8
May 11, 2019, at the historic SunnyBrook Orlando
isa.org
Ballroom in Pottstown, Pennsylvania. FC
Turbomachinery & Pump Symposia
Sept. 9–12
Send news and events for consideration
Houston
to Molly Rogers at mrogers@
tps.tamu.edu
endeavorbusinessmedia.com.

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www.flowcontrolnetwork.com June 2019 | 7

 Application Corner
By David W. Spitzer
Part 1: Measuring under vacuum:
Feeling the pressure
T
hree situations come to mind that
most technical people should
carefully consider: operation
under vacuum, measuring downward
liquid flow and gravity flow. These situa-
tions may not be routinely encountered
by the majority of practitioners, but they
can present significant issues that are
not readily apparent. Of course, if you
deal with these situations on a regular
basis, you will likely be comfortable with
proceeding at normal speed.
The vapor pressure of a liquid is the
pressure at which that liquid will boil.
Operating under vacuum conditions —
below atmospheric pressure — can cause
ordinary liquids such as water to boil at
room temperature. Processes often use
this phenomenon to an advantage when
drying heat-sensitive products by remov-
ing, say, water under a vacuum at room
temperature instead of potentially degrad-
ing the product by heating it to over 100°C
under atmospheric conditions.
Systems operating under a vacuum are
more likely than a pressurized system to
inadvertently operate below the vapor pres-
sure of the liquid. This is because liquids in
many process vessels in vacuum processes
operate at or near their vapor pressure
8 | June 2019
such that a small pressure reduction, such
as piping losses, or a small temperature
increase can cause the liquid to boil.
The installation of every instrument in
vacuum service should be analyzed in
detail to determine if a problem could
occur. For example, measuring the level
of a tank operating below atmospheric
pressure using a level probe installed in an
external stilling well might seem normal.
However, ambient conditions may make
the stilling well slightly warmer than the
liquid in the tank — operating at the vapor
pressure of the liquid — and cause the
liquid in the stilling well to boil, adversely
affecting the level measurement.
Read more on this topic next month. FC
David W. Spitzer is a principal at Spitzer
and Boyes, LLC, which offers engineering,
focused market research, writing/editing
white papers, strategic marketing consult-
ing, distribution consulting, seminars and
expert witness services for manufacturing
and automation companies. Spitzer has
written more than 400 technical articles
and 10 books about flow measurement,
instrumentation and process control. He
can be reached at 845-623-1830 or via
spitzerandboyes.com.
Flow Control
 Quiz Corner What is the rule of thumb for the amount of straight run
required upstream and downstream of a flowmeter?

A. 0 diameters upstream and 0 diameters downstream B. 5 diameters upstream and 3 diameters downstream
C. 10 diameters upstream and 5 diameters downstream D. 40 diameters upstream and 5 diameters downstream

R
esponses from students in my Industrial Flow
Measurement seminar (and many others) would
indicate that the rule of thumb for installation is 10
diameters of straight run upstream of the flowmeter and 5
diameters of straight run downstream of the flowmeter, so it
would seem that Answer C would be correct. However, there
is installed. All of the answers can apply to one or more flow
technologies and/or flowmeter designs.
Additional complicating factors
The ramifications associated with not having one rule of thumb
are many. Consider that many flowmeters are installed in
Vijay kumar/iStock

is no valid rule of thumb for installation because every flow- locations where limited space does not allow for the required
meter has straight-run requirements that result from multiple amount of straight run. In such instances, flowmeter perfor-
considerations, including the flowmeter technology, flowmeter mance would be degraded so another technology and/or flow-
design and the geometry of the piping in which the flowmeter meter with shorter straight-run requirements should be applied.

www.flowcontrolnetwork.com June 2019 | 9

Cover Series: Motors & Drives
Maximizing energy savings
through pump unit VFDs
Motor manufacturers offer protections to mitigate
effects of pulse width modulation so that benefits
of adding a variable frequency drive to a pump
system can be achieved.
By Patrick Hogg, Nidec Motor Corporation, and Jim Sanderson, Motion Industries
A
ccording to the International
Energy Agency (IEA), approxi-
mately half of the electricity used
globally is consumed in electric motors.
Industrial motor systems account for
about 70% of the manufacturing elec-
tricity used.
In the U.S., pump systems account for
about 40% of all industrial motor systems
electricity. The trend has been to design
more efficient pump systems for the high-
est return on energy savings.
In many applications, flow and pressure
are regulated using one of two ways. They
can be controlled mechanically using
throttle valves or by adjusting motor
speed using variable speed drives. A
throttling valve, which mechanically limits
the flow in a system, is both mechanically
and electrically inefficient.
The preferred way to adjust pump
speed and flow, therefore, is typically a
variable frequency drive (VFD). The VFD
electrically changes the frequency to that
of an AC motor. Motor speed is directly
related to frequency, while motor current
is directly proportional to the required
torque. As the speed of centrifugal pumps
is lowered, the required torque and motor
current drops dramatically.
Understanding pump
operation using VFDs
In centrifugal pump operation, flow
decreases in proportion to the drop in
10 | June 2019
speed. A 50% reduction in speed, in
other words, produces a 50% reduction
in flow. The pressure or head produced,
however, decreases by the square of the
speed. A 50% reduction in speed results
in a 25% reduction in pressure.
Because power consumption is related
to work, the relative work required is
greatly reduced when both the flow and
pressure are reduced. The power reduc-
tion is the cube of the decreased speed.
So when motor speed is reduced by 50%,
the power required is (0.5)3, or 12.5% of
the required motor torque and current,
compared to full-speed operation. This
is known as the Affinity Law.
Pump matching to the VFD
Dramatic energ y savings can be
achieved by reducing pump speed.
However, it remains critical to select
the correct pump for the application
based on needed flow and pressure.
As always, the pump speed-torque
curve must be evaluated. There are
mechanical limitations as pump speed
decreases. For example, volume
may be reduced to a point where
the pump is unable to meet
system requirements.
Variable speed motors pro-
vide more flexibility for using a
pump that meets current needs, with
possible increases in the future. A VFD
helps improve pump life by operating
Flow Control
 (Above) U.S. Motors
Vertical Hollowshaft As the speed of centrifugal pumps is
motor and VFD
provides flexible water lowered, the required torque and motor
flow options for a
cattle ranch in Texas.
current drops dramatically.
Courtesy of Nidec
(Left) The VFD in this below designed pressure limits. It also
system controls the provides the ability to ramp to speed,
lead/lag operation,
maximizing efficiency
which reduces mechanical shock or
and longevity of water hammers, and to match power
the pumps. to performance.
Courtesy of While VFDs deserve credit for helping
Motion Industries
systems maintain peak efficiency, they
also have the potential to damage the
motors they drive — unless steps are
taken to reduce their harmful effects.
Understanding the challenges
of VFDs on motors
The challenges posed by VFDs are related
to the pulse width modulation (PWM)
power waveform they use to modulate
the frequency and voltage supplied to a
motor. That, in turn, controls motor speed.
In VFDs, a rectifier converts AC to a DC
voltage, and transistors (switches) —
known as the inverter section — create
pulses to output a waveform that mimics
a sinewave at the desired frequency. The
www.flowcontrolnetwork.com
PWM switching waveform can affect a
motor’s winding insulation and bearing life.
More specifically, PWM can cause
motor windings to experience voltage
spikes well above their standard voltage
limits. On a three-phase AC line voltage,
for example, it takes about 8 milliseconds
for standard sinewave power to transition
from one peak to the next. PWM causes
dramatic spikes in voltage, pulsing from
minimum to maximum in less than 0.001
millisecond, or 1 microsecond (µs).
Because these spikes exceed the limits
of standard insulation, they can result
in rapid breakdown of motor insulation,
compared to what might be expected if
windings did not exceed the rated maxi-
mum voltage.
Wave reflection is another phenom-
enon that can affect peak voltages and
their effect on motor windings. Wave
reflection is a function of the time it
takes a wave to rise and the length of the
June 2019 | 11

VFDs use pulsing DC voltage to create an imitation
sinewave, which has the effect of building up a
differential charge between the rotor and stator.
cable between the VFD and the motor.
Reflective waves that bounce back to their
source can become additive to incoming
waves. The longer the cable, the greater
the wave reflection. Reflected waveforms
can build to a point of damaging the VFD
and motor. Consideration of this phenom-
enon should be taken into account when
the distance between VFD and the motor
it controls exceeds the VFD manufac-
turer’s suggested distance. Technologies
that allow for greater distances to occur
in the field can be added to the system.
Motor windings and VFD damage are
not the only issues affected by PWM.
Premature bearing failure can also be
attributed to fast-rising voltage pulses.
The high switching frequency inverters
used to achieve the required PWM wave-
form causes capacitive energy to build
between the rotor and stator.
If this energy is released on a path
through the motor bearings, it can cause
electrical discharge machining (EDM),
also known as fluting, which can cause
the bearing to overheat and potentially
fail prematurely.
The voltage differential between the rotor
and stator that results from use of PWM
waveforms on a standard inverter can also
affect an electric motor’s bearings.
Three-phase motors driven by standard
sinewave power have a balanced charge.
The PWM waveform, however, is not a
true sinewave. Rather, VFDs use pulsing
DC voltage to create an imitation sin-
ewave, which has the effect of building
up a differential charge between the rotor
and stator. Known as common mode volt-
age (CMV), the differential charge that
builds up between the rotor and stator
must be mitigated through shaft ground-
ing and correct system installation to
avoid damaging the bearing.
Protecting VFD-enabled motors
Aware of these challenges, many motor
manufacturers have created product lines
12 | June 2019
specifically designed to operate with a
VFD. These motors include specially
designed winding and bearing protections
that mitigate some of the effects a PWM
waveform can have on a motor.
The shift to VFDs has led to the addition
of inverter wire as a standard feature in
integral horsepower random wound motors.
Electric motor design and manufacturing
techniques have also undergone changes
to accommodate VFD applications, as well
as to eliminate shaft currents.
To protect against voltage spikes that
exceed their rated voltage, inverter duty
motors are designed for use with VFDs
by typically including inverter duty insu-
lation systems rated to handle the volt-
age spikes that occur. Insulation design
standards are regulated by the National
Electrical Manufacturers Association
(NEMA), which specifies the maximum
peak voltage each type of insulation must
withstand, as well as the minimum rise
time for power waveforms.
According to NEMA MG1 Part 31, the
windings on VFD-enabled motors with a
600 volts or less voltage rating must pro-
tect, at minimum, against a voltage spike of
3.1 times the rated voltage and a rise time
greater than or equal to 0.1 µs. Motors
with a voltage rating greater than 600
volts must protect, at minimum, against
a voltage spike of 2.04 times the motor’s
rated voltage with a rise time greater than
or equal to 1 µs.
To prevent CMV, bearings on these
motors require protection that provides a
low-resistance path to ground to mitigate
any charge buildup. This typically requires
mounting a shaft grounding device —
either externally or internally, per local
codes for the motor.
For additional protection, 100-plus
horsepower motors isolate one of the
bearings from the motor shaft to interrupt
circulating currents that would otherwise
add extra energy to the motor shaft. This
is typically accomplished by coating the
bearing mount with an insulating mate-
rial, thereby isolating the shaft from the
bearing. If the motor will be located in a
hazardous environment, the manufacturer
may insulate both bearings, but more
often, will insulate the coupling instead.
Getting to the root
of the problem
While motor protections like these are
helpful, they do not address the root
causes of PWM waveform damage. The
fact is, manufacturers often add these
protections because they cannot predict
where, how or when these components
will be installed.
When reviewing the system as a whole,
follow the manufacturer’s guidelines to pro-
vide correctly sized wire, filters and con-
duit. Refer to the manual to understand the
proper grounding requirements of the motor
and VFD. The following guidelines can help
achieve a successful design and installation
(always refer to the manufacturer’s manual
for any additional information):
VFD installation: The power cables that
connect the VFD to the motor should be
shielded and rated for use with a VFD.
The manufacturer should be able to rec-
ommend cables that are appropriate for
the system’s voltage and current limits.
Most distributors of VFDs offer a product
that meets these requirements.
Grounding: VFDs produce high frequency
noise. To reduce the damaging effects
of that noise, motors must be grounded
back to the drive. That requires a braided
type of grounding wire that grounds the
motor to the drive. At minimum, that wire
should be of the same size as a single
power lead and be located in the power
lead conduit. To obtain the best mitigating
effects, installers should consider using
multiple grounding wires.
Conduit selection: Power leads and
grounding wire should be housed in metal
conduit, which should be connected to both
the motor and drive without isolating either.
PVC, plastic or other insulating materials
are not recommended for connecting metal
conduit to a drive or motor terminal box. If
Flow Control
these materials are used, the metal con-
duit carrying the power leads and ground
cable must be properly connected to the
grounding circuit.
VFDs produce high frequency noise. To reduce
The VFD manufacturer may be able to
suggest other filtering options to further the damaging effects of that noise, motors must
reduce risk. be grounded back to the drive.
For existing systems, it is harder to get
to the root causes of PWM. Still, its dam-
aging effects can often be reduced with
system add-ons, such as:
• Load reactors: These inductive
devices slow quick rise times and
eliminate high peak voltages.
• Inductive absorbers: Some damag-
ing bearing currents can be reduced
using these inductive devices.
• dV/dt filters: These filters limit the
peak voltage to a motor.
• Sinusoidal filters: Similar to dV/dt
filters, these filters include tuning
electronics that match carrier fre-
quency for best output waveform.

Conclusion
Capitalizing on the benefits of adding a
VFD to a pump system is possible when
the entire system is reviewed for the
effects of PWM power before the proj-
ect is started. To achieve the greatest
protections, it is necessary to design and
install these components as an integrated
system. Understanding both the issues
and operational requirements of a VFD
system will lead to years of successful
operation. FC

Patrick Hogg is the appli-

cation engineering man-
ager of General Industry
and Integral Horsepower
Pumping at Nidec Motor Corporation.

Jim Sanderson is a divi-

sional electrical engineer
for Motion Industries,
providing application
solutions for Motion’s cus-
tomers for the past 30 years. For more
information, visit motionindustries.com/
flowcontrol and themotorspecialist.com.

www.flowcontrolnetwork.com June 2019 | 13

Cover Series: Motors & Drives
Motor management:
Intelligence made easy
Better motor performance and advanced monitoring can help
save energy costs, protect systems and improve safety.
By Stephen Zbytowski, Eaton
M
otors are the single largest
energy consumer — making
power management increas-
ingly apparent as energy continues to
increase and becomes costlier. Industrial
facilities look to automation as an inno-
vative method to better protect personnel
and equipment while minimizing down-
time due to the complexity of startup
and shutdown procedures.
To address these challenges, new tech-
nologies are improving operator safety
during commissioning and operation and
achieving better motor performance and
system reliability to help companies power
their facilities efficiently and safely.
Modern motor protection solutions can
provide added value compared to traditional
motor-starting using conventional overload
relays. Today’s motor management relays
and drives offer advanced protection and
monitoring options, alongside customized
starter control that can reduce wiring time,
complexity, space and material costs.
The bottom line is that products are
getting smarter, allowing facilities to get
the diagnostics and intelligence needed
to improve performance without the need
for a complete overhaul.
The future is here
Imagine combining the motors and drives
14 | June 2019
technologies into one product. The intel-
ligence of the drives would be combined
with the intelligence of the motor or
complement each other. They would no
longer be stand-alone components.
This is already happening with motor
management relays. Most industry play-
ers have the intelligence built in, so they
can monitor things like temperature and
torque, among others.
For example, Eaton is introducing
logic into its PowerXpert C445 intel-
ligent motor management relay, which
provides a high level of monitoring accu-
racy and protection for the entire power
system — from the incoming power
source feeding the motor all the way to
the individual pump or load. It protects
the motor, maximizes uptime, reduces
integration costs, enhances personnel
safety and offers a communications fea-
ture that allows for remote monitoring
and troubleshooting.
Motor management relays:
Controlling and protecting
the motor
A motor management relay can both
control and protect the motor. This elimi-
nates the need to wire complex circuits
to achieve desired control functionality.
These relays can be configured for multiple All images courtesy of Eaton
Flow Control
 The development of connected machines
is empowering users with real-time
monitoring along the production line to
improve productivity and reduce downtime.

control sources and starter profiles.
All control signals are sent directly to
the relay — with the contactor output
changing state based on both control
and protection.
A traditional overload relay has a fault
contact that only changes state and
opens in the case of a fault. Many over-
load relays still offer comprehensive pro-
tection features, opening this contact not
just due to a thermal overload, but also
due to other current, voltage and power-
based protections.
However, no matter the level of protec-
tion offered, the wiring method relies
on all control functionality taking place
outside the relay. The overload relay is
simply a normally closed fault contact
wired correctly in series with the control
circuit so that a protection event will stop
the motor. Also, drives allow for motor
protection against short circuits, lightning
strikes and other factors, and they reduce
energy costs by running the motor at the
appropriate speed.
A motor management relay removes
the need for extra wiring yet achieves the
same control requirements. A simple user
interface provides control and status indi-
cation. Control signals can also be sent
directly to the device over the network.
This is all achieved with a single cable
connection to the user interface and the
network. Motor management relays and
variable speed drives continue to save
on wiring time, cost and complexity, even
when traditional pilot devices are pre-
ferred for control.
Even in basic starter applications, this
simple technology can save facilities time,
money and space. Benefits increase as
starter logic becomes more complex,
such as two-speed or reverse applications
with multiple contactors or applications
involving other devices.
Conclusion
Motors are the single largest energy-
consuming device, and controlling them
to be more efficient can create untapped,
relatively easily obtained energy savings.
In fact, the two biggest savings are instal-
lation costs and energy conservation.
The development of connected machines
is empowering users with real-time moni-
toring along the production line to improve
productivity and reduce downtime. In new
technology such as motor management
relays, real-time intelligence is being
paired with online monitoring. This pro-
vides a platform for data analytics and the
opportunity to proactively identify poten-
tial problems to perform diagnostic and
prognostic calculations, having an impact
on uptime and performance — and ulti-
mately, the bottom line. FC
Stephen Zbytowski is
the product manager
for the soft starters and
motor protection relays at
Eaton. He has worked with industrial cus-
tomers to implement automation, motor
management and safety products for
more than 20 years. Zbytowski has expe-
rience implementing products for several
major manufacturers of automation and
motor control products. His knowledge
of overall equipment efficiency/effective-
ness, IoT and uptime assists customers
in selecting motor starters, communica-
tions, pilot devices, enclosed control,
PLCs and relays.

www.flowcontrolnetwork.com June 2019 | 15

Features: Bearings
Major causes of roller bearing
failure and prevention tools
Roller bearing reliability can be strengthened
with proactive maintenance strategies.
By John Bernet, Fluke Corporation
H
istorians believe varying forms of
rolling bearing elements have
existed for ages and were likely
used to assist workers in constructing the
Egyptian pyramids. One of the strongest
examples of early usage materialized in
1929. Roman ships from the first century
were retrieved from the bottom of Italy’s
Lake Nemi.1 Scholars examined a round
platform embedded with lead ball bearings
and believe the mechanism was designed to
rotate a life-sized statue on one of the ships.
Today, roller bearing mechanisms are
used in thousands of industrial, auto-
motive, marine and aerospace applica-
tions. Whether cylindrical, spherical, gear,
tapered or needle, roller bearings work to
reduce rotational friction to support radial
and axial loads (see Figure 1).
Lubrication is critical
to roller bearing life
Roller bearing failure has the potential to
shut down running equipment and possi-
bly entire plant operations. Roller bearings
require lubrication to reduce the metal-
to-metal friction between the rolling and
sliding contact areas. Letting lubrication-
related tasks lapse can ultimately mean
catastrophic equipment failure.
Lubricating helps disperse heat from
the bearing, remove wear particles and
contaminants from the rolling contact
areas, protect against corrosion and
increase bearing seal bonds.
Four of the top reasons roller bearings fail
results from poor lubrication or lack thereof.
Lubricant contamination
As shown in Figure 2, the prime reason
roller bearings fail to reach life expectancy
16 | June 2019
is due to lubricant contamination from
particles. To the naked eye, a lubricant
sample might look clean, but in fact,
contains tiny wear-causing contami-
nants, including dirt, dust, sand, metal
shards and other elements. Pollutants
can damage bearings, thus wearing them
prematurely. Furthermore, once the roller
bearing sustains damage, the condition
is usually irreversible, and no amount of
maintenance, except replacement, can
restore the bearing to its original state.
Particles can be introduced in countless
ways, including during lubricant production.
The amount of debris in newly produced oil
or grease can differ by as much as a factor
of 1,000. Large quantities can contain
even higher amounts. Particles can also be
introduced during maintenance or replace- and other proactive maintenance
ment, or because of wear, fatigue, aging methods to prevent wear.
and imbalance caused by leaks, worn seals 4. Ensure lubricant is clean. When
and other breaches. replacing grease or oil, equipment
Four principal ways to avoid particle should also be clean.
contamination include:
1. Purchase lubricants from a repu- Indicators of emerging
table company. Information about bearing failure
the product should be readily Regular preventive maintenance (PM) and
available including specifications. predictive maintenance (PdM) strate-
Depending on the application, evi- gies can help keep bearings operating.
dence should show that standards, Although designed to last, roller bearings
such as IEC, ASTM, ISO or DIN, are cannot rotate forever. Sooner or later,
up to date. they experience material fatigue.
2. Store lubricants indoors and keep Evidence of bearing issues appears in
them away from heat and other many forms, including:
possible sources of contamination. • Grooving: Contaminants wedged in
Lay drums horizontally. Select lubri- soft cage material can incise grooves
cant usage based on the purchase in rolling elements. Generates improper
date, i.e., oldest to newest. rolling contact geometry. Reduces
3. Test equipment for imbalance, mis- bearing service life.
alignment and other conditions. • Noise: Bearing damage can be distin-
Use vibration analysis, thermography guished by unusual yet characteristic
Flow Control
 (a) (b) (c) (d)

sizovin/iStock
(h)
(e) (f) (g)
Figure 1. Bearing shapes: a) deep groove ball bearing, b) angular contact ball bearing,
c) self-aligning ball bearing, d) cylindrical roller bearing, e) tapered roller bearing,
f) spherical roller bearing, g) needle roller bearing, h) thrust ball bearing
Illustrations from SKF Bearing Catalogue. Image courtesy of Solano-Alvarez, Wilberth.
(2015). Microstructural degradation of bearing steels, Fig. 2. https://www.researchgate.
net/figure/Bearing-configurations-30-a-deep-groove-ball-bearing-b-angular-contact-ball_
fig1_281127914 [accessed 29 Apr, 2019].

noise using sound detection instru- to blue. Temperatures over 400°F

ments during operation.
• Peeling: Caused by hairline cracks.
Condition consists of small areas of
flaking due to insufficient lubrication
or infiltration of foreign matter.
• Spalling: Pitting or flaking away of
bearing material. Primarily occurs on
races and rolling elements. Always
accompanied by an increase in
vibration. Condition will continue to
spread with ongoing operation.
• Overheating: Ring discoloration of
rolling elements and cages from gold
can anneal ring and rolling element
metals, reduce bearing capacity and
cause early failure. High tempera-
tures can also degrade or destroy
lubricant.
• Pitting: Small areas of flaking or
peeling caused by hairline cracks.
Condition may be caused by foreign
matter infiltration or insufficient
lubrication.
• Vibration: Bearing irregularities can
be analyzed by measuring the vibra-
tions of an operating machine using
a frequency spectrum analyzer
to calculate the magnitude of
vibration and frequency distri-
bution. Test results help deter-
mine the likely cause of the
bearing abnormality.

Figure 2. Top reasons

roller bearings fail
Courtesy of
Fluke Corporation

www.flowcontrolnetwork.com June 2019 | 17

 Type Causes
Contamination • Foreign matter in lubrication
or clearing solutions
• Contaminants from work areas
and dirty hands or tools
Corrosion • Condensation
• Moisture
• Broken-down or
low-quality grease
• Poor wrappings
Excessive loads • Bearing overload
False brinelling • Rapid movement of balls in a
raceway while equipment is idle
wears away lubrication
• Lack of rotation in the bearing
prevents fresh lubricant from
entering the bearing
Fatigue (spalling) • Overloading, excessive preload
• Tight inner-ring fits
Fit • Tight fit: excessive loading of
the rolling element when
interference fits exceed the
radial clearance at operating
temperatures
• Loose fit: micro-motion
between fitted parts
Improper mounting • Bearings mounted by applying
pressure or blows to the outer
race or into the housing by
pressing on the inner ring
• Loose shaft and housing fits
• Excessively tight fits
• Out-of-round housings
• Poor finish on the bearing seat
Lubrication • Insufficient lubrication
• Improper lubricants
• Excessive temperatures that
degrade lubricant
Misalignment • Bent shafts, out-of-square shaft • Overheating and
shoulders, out-of-square
spacers, out-of-square clamping • Wear path not parallel
nuts and improper installation
due to loose fit
Table 1. Causes, clues and cures for premature roller bearing failure
18 | June 2019
Clues
• Denting of rolling elements
and raceways
• Vibration
• Brown or red stains on rolling
elements, cages or raceways
• Increased vibration followed
by wear
• Increased radial clearance
• Loss of preload
• Heaving rolling element
wear paths
• Overheating
• Widespread fatigue areas
• Linear wear marks in the
axial direction at the rolling
element pitch
• No raised edges, unlike marks
due to incorrect mounting
• Fracture of running surfaces
• Loss of small, discrete
particles of material from
the inner ring, outer ring or
rolling elements
• Increase in vibration and noise
• Spalling will spread with
continued operation
• Tight fit: heavy rolling-element
wear path in the bottom of
the raceway, overheating or
an inner-ring axial crack
• Loose fit: note any generation of
fine metal particles, which
leaves a distinctive brown color
• Denting
• Wear
• Cracked rings
• High operating temperatures
• Early and premature failure
• Overheating
• Discoloration
• Excessive bearing wear
separator failure
to raceway edges of the
nonrotating ring
Cures
• Filter lubricant
• Clean work areas, tools,
fixtures and hands
• Divert corrosive fluids
• Select integrally sealed bearings
• Use external seals for particularly
hostile environments
• Use appropriate bearing material
in corrosive environments
• Reduce load
• Use bearings with
larger capacity
• Eliminate or absorb
external vibration
• Use lubricants containing
anti-wear additives
• Replace bearings
• Redesign using a bearing with
greater calculated fatigue life,
internal clearances and proper
shaft and housing standards
• Make sure a proper clearance
is selected to avoid fit issues
• Refer to the manufacturer’s
installation guide
• Follow specified mounting
instructions
• Train employees to ensure they
understand the difference
between improperly and
adequately installed mounting
• Mount bearings with a press
fit on the rotating ring
• Use the compatible and
precise amount of lubricant
• Avoid grease loss
• Schedule regular relubrication
• Inspect shafts and housings
for runout of shoulders and
bearing seats
• Use precision-grade locknuts
Flow Control
Premature roller maintenance tasks, roller bearings have strategies, M&R teams can further ensure
bearing failure a better chance of reaching their full poten- roller bearing reliability. FC
Learning to troubleshoot bearing prob- tial. When predictive maintenance tools,
lems is a crucial part of any maintenance such as vibration sensors, are integrated References
program. As many as 13% of industrial with computer maintenance management 1. Britannica, T. E. (2011, June 09).
motor failures happen because of bear- software (CMMS), maintenance teams can Lake Nemi. Retrieved from https://
ing failures. Moreover, 60% of equipment set acceptable boundaries for equipment www.britannica.com/place/Lake-
breakdowns involve bearing wear. operation, import and view continuous Nemi.
Most defects result from a combination readings and graph results. Additionally,
of failure modes, and each failure is usu- the system can be configured to automati-
ally due to a mixture of causes. cally trigger an email or generate a work John Bernet, a mechani-
order — should equipment exceed param- cal application and prod-
Vibration: A chief precursor eters. With cloud technology, maintenance uct specialist at Fluke
to bearing failure and reliability (M&R) teams can view data Corporation, works with
Usually, before bearings fail, the problem in real time from anywhere, any time. customers from all industries to help them
appears in the form of vibration. For Premature roller bearing failure can successfully implement their reliability pro-
example, roller bearings will cause vibra- affect business, the environment and grams. He is a former U.S. Navy nuclear
tion each time they pass over a damaged personnel — should the bearing cause power plant electrician and has more than
or pitted roller bearing race. Without being an explosion. Even the most comprehen- 30 years of experience in the maintenance
harmful or invasive, vibration analysis sive maintenance program can result in and operation of commercial machinery.
provides the most detail about what is undetected faults, leading to unexpected Bernet holds a Category II Vibration Analyst
happening inside machinery by detect- failures. However, through proper care and certification and is a Certified Maintenance
ing minuscule changes in acceleration, with the help of proactive maintenance Reliability Professional (CMRP).
direction or velocity that may indicate
bearing wear, installation error or other
mechanical problems.
Wireless condition monitoring vibration
sensors installed on a bearing housing
can provide maintenance teams with
actionable data. Technologically advanced
tools can help further ferret out more
complex issues that might show up in the
overall vibration analysis. It can then be
used to decide whether additional analy-
sis is required and if relubrication, repairs
or replacements are needed.
Infrared (IR) thermography can also be
used for oil analysis to discover if wear
particles or other contamination-causing
issues are present in the roller bearing.
Thermal imaging sensors can be set in
place to monitor equipment condition
safely. Measurements are taken from
a distance and uploaded to the cloud,
where technicians can view them on a
smart device, such as a mobile phone,
tablet or computer. The data can then
trend temperature changes over time and
help determine if bearings are operating
optimally or headed for a breakdown.

Boost roller bearing life

using PM and PdM strategies
Fortunately, by carrying out preventive

www.flowcontrolnetwork.com June 2019 | 19

Features: Control & Automation

An effective IIoT entry point

is through software applications
Purpose-built apps designed for specific assets are a simple,
cost-effective way to improve plant connectivity.
By Ron Fleissman, Emerson Automation Solutions

T
he industrial internet of things
(IIoT) is not a new concept, yet
universal adoption has not been
seamless or quick. The adoption of new
technologies that enable wireless data
gathering and analysis has been slow,
especially in industries that deal with
highly sensitive materials and processes
or legacy equipment that is still func-
tioning adequately. Primary concerns
include the security of the data gathered
and where it will be stored, the cost of
retrofitting existing equipment and the
reliable functionality of the software.
In weighing the options for IIoT adoption,
there are many points to consider, including
whether there are smaller, less expensive
changes that plant management can consider
as a first step, as well as the measurable
benefits that justify the initial investment.
One such low-cost option to consider
is the use of purpose-built apps that dis-
play critical data on a dashboard for spe-
cific plant assets.
Stepping up to the future
Many refineries and chemical plants operate
with legacy equipment that does not nec-
essarily have digital capabilities. And while
the idea of going digital makes for a nice
boardroom presentation, the reality is, in
most scenarios, upgrading to an integrated
and connected plant takes a considerable
investment, re-engineering of the plant lay-
out and upgrades to IT and equipment.
When considering profit margins and
operational costs, which are always top of

20 | June 2019 Flow Control

 to engineers, requires stepping up to
some form of digitizing and interconnect-
ing the plant as well. Not only because
of the digital background of the younger
generation of workers, but also because
not all the jobs left by the older generation
will be backfilled, meaning there will be
more work to do for fewer people. To meet
the needs of the workload and to ensure
the safety and productivity of the plant,
new systems need to be put in place.
Data security first
One of the biggest concerns that manu-
facturers have about adopting digital
automation technology is security. What
happens when information is shared
wirelessly? What about cloud storage?
Will the data gathered from meters and
transmitters be safe or will it be vulner-
able to hackers? With recent reports
about data breaches and datamining,
the risk of data loss to outside entities
is certainly real.
A surprisingly simple solution to miti-
gating that risk is the use of devices
metamorworks/iStock with data diodes that establish a uni-
directional security gateway. Combining
mind, the conversation becomes more chal- this with appropriate protocol translations
lenging but not impossible. It requires careful constructs simple systems that allow for
planning and research to determine the best the highly secure transfer of data from
options for modernizing an older plant. gateways that talk directly to sensors,
such as WirelessHART gateways found
The next generation on many of today’s newer flowmeter
While conversations around digitizing transmitters.
operations are happening, there is another Using these types of devices allows a
important development that has an impact plant to establish a secure perimeter for
on the decisions involving IIoT: changes in
the workforce.
A significant segment of workers are
reaching retirement age, and when they
Courtesy of Emerson Automation Solutions
leave, they will take with them decades
worth of skills and knowledge that cannot
be easily or quickly taught to new hires.
Also, many younger workers are digital
natives and are accustomed to having
data at their fingertips on digital devices.
This environment has contributed to a
growing skills gap in manufacturing that
will have a significant effect across indus-
tries; it is predicted that millions of jobs
will remain unfilled by 2025.
Attracting and integrating the new gen-
eration of plant workers, from technicians
www.flowcontrolnetwork.com
data transfer from Coriolis flowmeters,
for example, within the plant. This means
data can be collected securely from the
cloud without physically having to check
the meter.
Software applications
provide solutions
With data diodes and secure gateways
in place on metering equipment, it then
becomes a matter of accessing the gate-
way to collect the data. Several large
technology and manufacturing companies
are seeing the value of apps — software
applications that can live on a desktop,
laptop, tablet or phone for easy access.
These apps, just like the ones found on
a smartphone, allows instant access to
data from every designated device.
It would be a nearly impossible task
for engineers and technicians to sift
through the reams of data that meters
generate; however, well-conceived
designed software can instantly sift
through and compile data into action-
able information, such as:
• The health of the meters
• How much is flowing through
each meter
• Which meters are not performing
within set parameters
• An alert that warns of critical issues
requiring immediate attention
This capability relieves a considerable
burden on technicians and engineers,
because there may not always be an
June 2019 | 21
option to quickly glean changes hap-
pening in a meter unless they are big
enough to cause a noticeable problem
down the line.
Adding to that benefit is knowing which
meters are not functioning correctly
based on what the app displays, mean-
ing users no longer need to check each
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and every meter in the field. This saves
time and money and ensures safer work-
ing conditions for personnel.
A purpose-built app for each specific
asset — displaying on a dashboard and
sending critical alerts when needed — is
an easy and cost-effective way a plant
can make forays into IIoT.
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Connected plant benefits
Greater plant connectivity ensures that
data can be acted upon immediately.
Relevant information is culled and pushed
out to the digital dashboard so everyone
with access can view it — not just in
terms of the health of the meters, but
also the state of production.
Using a collection of easy-to-deploy
applications optimizes productivity and
ensures greater accuracy in measurement.
This has benefits for not only plant opera-
tions, but also for custody transfer and for
the accurate automated measurement of
additives that can be adjusted based on
whether readings fluctuate. Furthermore,
recorded and stored data provide an audit
trail of plant operations that can be used to
generate reports needed to meet regula-
tory and customer compliance standards.
A winning proposition:
Software applications
In this data-driven world, a competitive
advantage is gained by those who can
harness and act on information the fast-
est. The ability to quickly and easily distill
data and translate it into clear, useful
and directly actionable information is key.
Leveraging the full potential of available
intelligence from plant assets can often
seem like a daunting proposition. That’s
where well-designed software applications
come into play. Software applications offer
intelligence, security, scalability and imme-
diate insights, which in turn will allow for
peak process optimization and protection
of plant operations and assets. FC
Ron Fleissman is a software product mar-
keting manager at Emerson Automation
Solutions. He has extensive experience
working with technology and software
startups in New York City. Fleissman
graduated from Syracuse University with
a degree in political science.
MORE For more on control
ONLINE and automation, visit
flowcontrolnetwork.com
Flow Control
Features: Cleaning & Safety
Case study: Cleaning with
controlled gas explosions
A U.S. plant partners with an industrial cleaning company and a
blast measurement specialist for emergency component cleaning.
By Fabian Hössli, Kistler
W
hen using controlled gas explo-
sions to clean industrial
plants, cleaning is carried out
while the plant is running and in com-
pliance with strict safety regulations.
This process has been used in almost
every sector of industry where fuel-fired
energy and power generation plants are
in operation. Examples include waste-fed
heating plants, biomass power stations
and hazardous waste incineration plants,
as well as chemical and pharmaceutical
facilities. Ash and slag deposits must be
removed regularly from plant components
such as boilers, catalytic converters and
reactors; otherwise, performance will be
reduced, faults will occur and operators
will be faced with high outage costs.
The Bang&Clean system for cleaning
with controlled and dosed explosions was
developed in 2000 for cleaning indus-
trial plants and components. Benefits
include long service lifetimes for plant
www.flowcontrolnetwork.com
components and avoided downtime.
Another advantage: Plant components
continue to operate during the cleaning
process to avoid shutting down the plant,
thus saving costs.
How it works
With Bang&Clean’s explosive cleaning
system, first, the specialists introduce a
water-cooled lance — prefitted with a
special bag — through the boiler’s doors
or portholes near the heating surface to
be cleaned. The bag is inflated with a
combustible gas mixture, which is then
ignited to cause an explosion. This gener-
ates a highly dynamic pressure wave and
causes vibrations in the pipes and walls
that dislodge deposits of ash and slag.
Throughout the process, the top priority
is safety for people and machines. The
cleaning equipment is CE-compliant, and
it is inspected by the German Federal
Institute for Materials Research and Testing
Figure 1. Bang&Clean’s cleaning
process has been used in
industries where fuel-fired
energy and power generation
plants are in operation.
All images courtesy of Kistler
(BAM). Certified experts only prepare the
explosive gas mixture a few moments
before the detonation in the boiler to
ensure plant and personnel safety.
Application: Emergency
cleaning near a nuclear
power plant
Most of the company’s cleaning system
deployments are planned well in advance,
but there are occasional emergencies or
special assignments with only a few days or
hours notice. This is what happened when a
U.S. plant operator contacted the company
with a request to clean its components.
“That really was a very special case,
because our customer’s facility was in the
immediate vicinity of a nuclear power plant,”
said Markus Bürgin, founder and managing
director of Bang&Clean Technologies AG.
“To obtain approval for cleaning the plants,
our customer had to submit advance proof
that the cleaning method was safe.”
June 2019 | 23
 Bang&Clean did not have the measure-
Plant components continue to operate during ment expertise required to provide the
the cleaning process to avoid shutting down the necessary proof, so Bürgin called in a
cooperation partner, Kistler, a company
plant, thus saving costs. with application expertise in blast pres-
sure measurements.
“When we received this inquiry from
Boiler
the U.S. at such short notice, we imme-
diately realized that we couldn’t handle
this project unless we called in the mea-
Equipment surement technology specialists from
Winterthur [Switzerland],” said Bürgin.
Ignition Given the time pressure, Bang&Clean
and Kistler needed to prepare a mea-
surement campaign within the short-
Lance
est possible time. Philipp Schenkel
and David Weber, Kistler’s develop-
ment engineers, provided support and
advice for the team headed by Bürgin
throughout the project. To ensure cor-
rect measurement of the pressure val-
ues required, they opted for a relatively
Figure 2. Bang&Clean’s cleaning process simple test setup in an experimental
gallery at Lungern.

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Deepwater
Pipelines Technology for offshore
oil and gas operations

Also Inside

Accuracy and traceability

of flow measurement

How the floating ball

valve works

Condition monitoring of
heat-transfer pumps

APRIL 2019 • Vol. XXIV, No. 4

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24 | June 2019 Flow Control

 “For the test setup, we attached a bag
to a lance, filled the bag with a gas mix-
ture and then detonated it,” said Weber.
The parameters under examination
included different distances, the gas vol-
ume and the bag material. About 30 test
cycles were needed to arrive at a full under-
standing of the ignition processes and the
propagation of the pressure waves.
To measure the pressure values, Weber
and Schenkel chose the Type 6233A pen-
cil probes from Kistler. These piezoelectric
sensors are ideal for measuring highly
dynamic pressures in blast tests.
“In our tests, we aligned the pencil
probes radially in relation to the deto-
nation source,” said Schenkel. “That
allowed us to measure the pressure
of the propagating blast wave directly
and precisely.”
www.flowcontrolnetwork.com
As the name suggests, the sensors have
a characteristic pencil shape. This fea-
ture minimizes the influence of the sensor
geometry on the propagation of the blast
wave and the measured signal. Rugged
structural design and minimal bending
sensitivity make these sensors ideal for
measuring high-precision pressure sig-
nals in harsh environments. An integrated
amplifier circuit (IEPE) converts the charge
signal into a voltage — another advantage
for applications with severe vibrations.
Results
“Thanks to Kistler’s measurement results,
we proved that our explosive cleaning sys-
tem poses no danger either to people or
the environment,” said Bürgin. “So we were
able to carry out the cleaning operations at
our customer’s plant safely and promptly.”
Figure 3. Pencil probes from Kistler measure
highly dynamic pressures in blast tests.
And there was another benefit: The
measurement results helped Bürgin and
his team achieve a better understanding
of the product and its effectiveness. For
this purpose, Bürgin is planning addi-
tional measurement campaigns and
taking advantage of Kistler’s expertise
for those measurements also. FC
Fabian Hössli is the product manager
of High Speed Dynamics at Kistler.
Hössli has worked as an electronics
engineer for various companies and
was product manager at Dormakaba
Holding AG before he joined the
Kistler Group.
June 2019 | 25
Innovation Awards

Badger Meter
Dynasonics TFX-500w Ultrasonic
Clamp-on Flow Meter

2019 The TFX-500w Ultrasonic Clamp-on Flow Meter mea-

Innovation Awards Nominees
Each year, Flow Control accepts nominations for its
Innovation Awards program to demonstrate how the
fluid handling industry is keeping up with evolving
technology. The entries recognize the importance
that companies place on continued improvement and
investments in research and development for innova-
tive solutions. Read about the nominees here, and then
go to flowcontrolnetwork.com/innovationawards to cast
your vote for the 2019 honorees. The deadline to vote
is June 30.
sures water flow bidirectionally in pipes 10 inches or
smaller. By clamping on the outside of the pipe, the
ultrasonic meter installs without cutting or tapping the
pipe. Designed for noninvasive, ultrasonic transit time
flow measurement, the meter accurately determines
the rate, total and velocity of water flow. With a large,
easy-to-read display, the meter provides Modbus RTU
and BACnet MS/TP connectivity and integrates with
the Badger Meter BEACON and AquaCUE Advanced
Metering Analytics (AMA) cloud-based software
suites. The meter can be programmed through the
front panel or USB cable using SoloCUE Flow Device
Manager software.
The TFX-500w meter can be retrofitted in existing
installations. It has no pressure head loss, no contact
with internal liquid and no moving parts to maintain.

Emerson
Micro Motion 4200 2-wire Transmitter
The Micro Motion 4200 Coriolis 2-wire flow and density transmitter offers up to a 4-inch
line size to accommodate larger flow rates that require a 2-wire Coriolis meter. Smart
Meter Verification is standard, along with zero verification. Real-time clock facilitates
troubleshooting by time-stamping process data, audit trails and Smart Meter Verification
reports. The touch control display provides ease of use and lowers commissioning time.
The transmitter also offers a remote mount option.
The 2-wire Coriolis meter uses the existing wiring without the need to run additional
wiring, scaffolding, conduit, AC panels and transformers, reducing complexity, length of
time and cost for retrofit or plant expansion projects. The transmitter housing is engi-
neered to provide easy access for installation, mounting and maintenance. The intuitive
interface allows full commissioning, configuration and operations through the display.

26 | June 2019 Flow Control

Endress+Hauser
Proline Prowirl F 200
Proline Prowirl F 200 is a multivariable vortex flowmeter for inline wet steam mea-
surement, primarily designed for steam, gases, liquids and cryogenic fluids. With
loop-powered technology, it enables seamless integration into existing infrastruc-
tures. Heartbeat Technology ensures process safety.
The Prowirl F measures volume flow, mass flow, corrected volume flow, energy flow,
heat flow difference, temperature and pressure. It is able to measure steam quality for
improved energy efficiency as well as plant and personnel safety. It offers operational
safety in hazardous areas and can be used in Safety Instrumented Systems (SIS) in
accordance with IEC 61508 and IEC 61511. It features lifelong calibration when used
in nonabrasive and noncorrosive media due to its patented capacitive sensor. The new
design allows flexible orientation and installation of the pressure transmitter.

EXAIR Corporation
No Drip External Mix Narrow Angle Flat Fan Atomizing
Nozzle 1/8 NPT
The No Drip External Mix Atomizing Spray Nozzles positively stop liquid flow when com-
pressed air is shut off. They are ideal where no post-spray drips are permissible. Three
liquid patterns are available: round, narrow angle flat fan and wide angle flat fan pat-
terns. They are used for pressure-fed applications where precise liquid flow is needed.
External nozzles can be used on liquids up to 300 centipoise. The newest 1/8 NPT
versions come in 5 different flow rates.
EXAIR’s no-drip liquid air nozzles use the supply air to operate the liquid valve and
create the atomized liquid pattern. This eliminates the separate pilot line and the addi-
tional compressed air required to operate the liquid valve. Air and liquid flows adjust
independently without drips, which conserves resources and chemicals or coatings.

Fluid Components International (FCI)

ST80 Series Thermal Mass Flow Meter
The ST80 Series Thermal Mass Flow Meter featuring Adaptive Sensor Technology (AST)
is a rugged thermal dispersion technology air/gas mass flowmeter that combines feature-
rich electronics with application-matched flow sensors. It features a robust transmitter
enclosure and a broad selection of process connections for long service life and ease
of installation. The transmitter’s extensive and flexible I/O capabilities ensure a match to
current and future DCS, PLC, SCADA, recorder or alarm system. The standard transmitter
comes with multiple outputs: two NAMUR NE-43 compliant 4-20 mA analog outputs,
HART (v7) and Modbus, and a USB port plus FCI software for PC interfacing.
AST is a hybrid drive that combines both constant temperature (CT) and constant
power (CP), plus a CP-only mode, for two field-changeable measuring techniques in
one flowmeter.

Fluke Corporation
Fluke 710 mA Loop Valve Tester
The 710 mA Loop Valve Tester features preconfigured valve tests for reliable, repeat-
able testing. The built-in routines include: manually changing the mA signal and
viewing the HART position and pressure variable information; full range ramping of
the mA signal from 4 to 20 to 4 mA while recording the 0-100-0 percent position
or the pressures applied that move the valve from 0-100-0 percent. It also includes
stepping the mA signal on the input to the valve in steps and evaluating the valve’s
response to the mA input changes.
Speed tests determine how fast the valve can open or close, and bump and partial stroke
tests help test valves over a portion of their range so they can be tested in a live process.

www.flowcontrolnetwork.com June 2019 | 27

 GF Piping Systems
Signet 9950 SmartPro Dual Channel Transmitter
The Signet 9950 SmartPro Dual Channel Transmitter offers multiple measurement
readings in one transmitter. It allows for automatic pH glass impedance measure-
ment, setting of broken glass detection from 1 to 2000 megaohms and reading of
data stored in all Signet DryLoc pH/ORP electrodes.
The new Conductivity Module allows the 9950 to monitor two different conductivi-
ties with a single module. The Modbus Output Module provides secondary mea-
surements such as temperature from pH or conductivity/resistivity measurements,
as well as totalizer values for flow. New software enhances the derived function
measurements. It can now calculate the sum, difference or ratio between two similar
measurements or, for conductivity or flow measurements, determine efficiencies in
reverse osmosis systems. It also provides the ability to mix and match secondary
measurements in the calculations.

Ham-Let
IoTH800 Smart Valve
The Internet of Things H800 Smart Valve (IoTH800) features constant monitoring,
management and control of position/state indication, pressure, flow, humidity and
temperature. Due to its array of sensors and capabilities, it can be activated by trig-
gering scenarios such as downstream pressure drop (line burst), high temperature
(fire) or vibration, simultaneously sending an alert to the control room.
The IoTH800 is compatible with a range of industry 4.0 standards (e.g., Modbus,
LoRa, BLE), easing interoperability with an existing system. Integrating with IoT cloud
platform allows immediate response for safety events, machine learning and opti-
mization, machinery and equipment protection and device tracking. As an all-in-one
product, the IoTH800 Smart Valve eliminates possible leakage sources cause by
other sensors and instrumentation used with a regular valve.

KROHNE Inc.
OPTISONIC 7300 Biogas Ultrasonic Flowmeter
The OPTISONIC 7300 Biogas Ultrasonic Flowmeter — for the measurement of dry
and wet (raw) biogas with variable composition — features a pressure sensor, along
with the standard temperature sensor, that can be ordered optionally and comes
mounted on the flow tube. Combined with the integrated flow computer, the addition-
al sensor provides advanced biogas measurement. A temperature sensor in combina-
tion with the measured velocity of sound enables direct measurement of methane
content via calculation of the molar mass. Using an additional pressure sensor, it can
provide calculation of gas flow volume to standard conditions.
The biogas flowmeter can be used for any gas flow measurement, including vent
gas applications in oil and gas production. The integrated sensor options simplify
installation, while the on-board flow computer allows the output to be set to a vari-
able, e.g., methane content.

L.J. Star Incorporated

The LumiFlo LED Light
The LumiFlo LED Light is designed to improve the lighting of full-view sight flow indica-
tors in process fluid lines. It easily attaches to most inline full-view sight flow indica-
tors, allowing operators to clearly see color, flow and particles moving through the
sight glass to visually inspect product quality, clarity, viscosity and consistency. It
uses long-life LEDs for ideal light and optimal color temperature for a clear view of
processes in the brewery, chemical, pharmaceutical, biotech and food and beverage
processing industries.
The LumiFlo LED light is designed to prevent microbial and mildew growth of the
silicone using nanomaterial additives. It also allows better visual inspection and saves
time during cleaning.

28 | June 2019 Flow Control

Sage Metering Inc.
Paramount Thermal Mass Flow Meter
The Paramount Thermal Mass Flow Meter features the Sage Prime’s display and
circuitry with a NEMA 4X enclosure, which safeguards the meter against harsh envi-
ronmental elements and provides corrosion protection. The rear compartment of the
display is separate from the electronics and has large, well-marked terminals that
are easy to access. It also features a mini USB port that permits the user to quickly
reconfigure the meter in the field while using SageCom software. The meter powers
with 24 VDC.
The Paramount’s display has a high-contrast photo-emissive OLED (organic LED),
demonstrating flow rate, total and temperature. The flow rate displays in a horizontal
bar graph. The meter is available in an integral (Model 401) or remote style (Model
402). The remote-style meter has lead-length compensation up to 1,000 feet and
an explosion-proof junction box.

Siemens Process Instruments

SIMATIC Process Device Manager - Maintenance Station V3.0
SIMATIC PDM Maintenance Station (MS) V3.0 is a universal, nonproprietary tool for the
configuration, parameterization, commissioning and monitoring of smart field devices.
The MS is available as a standalone system. It can run independently of both the cus-
tomers’ automation control projects and with complete autonomy from the PLC/DCS
process control systems being used.
The information from SIMATIC PDM is prepared in the SIMATIC PDM MS and supple-
mented by functionalities such as overview or work progress lists; overview, segment
and detail screens; condition logs; parameter data archiving; global and device-specific
message lists; and cyclic functions for reading and exporting field device information such
as overview displays and progress lists. The system is also expandable via accessory
programs that focus on specific needs of specialized components like valves and pumps.

United Electric Controls

Vanguard WirelessHART Gas Detector Version 1.2
The Vanguard WirelessHART gas detector can monitor the presence of toxic or com-
bustible gases for approximately five years without a battery replacement. Version
1.2 incorporates new features including more mounting options, more intuitive con-
figuration and access to diagnostics. It features an option for interchangeable sensor
heads, which makes it easier to monitor different gases at different times, a new
sensing head for carbon monoxide and installation options that do not require hot
work permits, including magnetic mounting and adjustable clamp mounting.
Expanded temperature operating range and enhanced stability across temperature
ranges enables performance in extreme temperature conditions. Minimal zero shift
with changing ambient temperature reduces the chance of false alarms and provides
faster gateway connections. Updated WirelessHART commands allow quicker con-
nectivity to networks and system commissioning.

VorTek Instruments
VorCone Meter
The VorCone Meter is a robust steam quality and mass flowmeter. It is a hybrid of the
vortex and cone meter designs. The combined use provides more information. With
two unknowns, i.e., steam quality and total mass flow, cross-referencing the two
primary meter signals produces the information to meter the quality and flow rate
in real time. The meter also has the option of a cone meter pressure field analysis
verification system.
Combining two metering subsystems produces two different primary signals, allow-
ing the production of two outputs, depending on the application. In single-phase
applications, the VorCone can output the mass flow and fluid density. In two-phase
flow, such as saturated steam, it can output steam quality and steam vapor flow.

www.flowcontrolnetwork.com June 2019 | 29

Trade Shows & Events
EASA 2019 spotlights
electromechanical industry trends
and outlook
T
his year’s Electrical Apparatus
Service Association Inc. (EASA)
Convention will be held June 30–
July 2 at the Mandalay Bay Resort and
Casino in Las Vegas.
In addition to the exhibition hall, the
event will feature the New Product
Theater, which provides EASA exhibitors
an opportunity to show attendees their
latest products with demonstrations and
presentations. The theater will be held
1–3:50 p.m. on June 30 and 12:30–3:50
p.m. on July 1.
EASA is an international trade organiza-
tion of more than 1,800 electromechani-
cal sales and service firms in nearly 80
countries. Through engineering and edu-
cational programs, EASA provides mem-
bers with a means of keeping up to date
on materials, equipment and technology.
This year’s convention will feature doz-
ens of lectures, forums and presenta-
tions — as well as a tour of the Hoover
Dam and a behind-the-scenes tour of
Mandalay Bay. Some of the sessions and
presenters include:
Final Assembly and Testing
of DC Machines
This session will teach attendees what
to do when assembling and testing a DC
machine. Especially for those without a
dynamometer, there are specific tests
that prevent the type of mistakes that
can cause a motor to arc, spark or not
run when the customer installs it. Topics
30 | June 2019
covered will include brush neutral, inter-
pole polarity, compound wound machine
do’s and don’ts and lead markings.
Kickoff Lunch and
Opening Remarks with
Keynote Speaker Mike Staver
Author and leadership coach Mike Staver
will teach attendees how to influence
their followers. Topics include: the pri-
mary motivator of all people, three things
every leader can do to ensure leadership
failure and six steps that will ensure effec-
tive execution.
Open Forum on Emerging
Technologies and IIoT
Topics of discussion will include:
• How will IIoT impact EASA members
• Why these topics impact all members
• Who owns the data?
• What about cybersecurity?
• How do you assess the technology
and which manufacturers or
distributors to work with
Case Studies in
Failure Analysis
This session will examine four electric
motor failures and discuss the clues to
solve them. It will include:
• How to evaluate evidence
correctly and avoid
common errors
• How to correctly determine the
chronology of the failures
EXHIBITION SCHEDULE
Image courtesy of FC staff
Sun., June 30, 12:30–5 p.m.
Logo courtesy of EASA
Mon., July 1, 12–4 p.m.
Tues., July 2, 9 a.m.–12 p.m.
easa.com/convention
• The importance of identifying
the failure quickly
• Involving the customer in the
process to avoid confusion
• Applying solutions to prevent
future repeated failures
Industrial Economy
2019 and Beyond
This session will discuss the business
cycle status of the global economy and
where it is heading. Some key takeaways
will include:
• Review of short- and long-term
economic forecasts
• How the forecasts will directly
impact the EASA industry
• Business cycle phases and what
they mean to members
• Leading economic indicators that
are most important to watch
• Economic insight on inflation,
interest rates and taxes
• Time-sensitive current events of
public concern and how to expect
them to impact the industry, as
well as recommendations for
moving forward
Open Forum:
Management Topics
Topics run the gamut from recruiting and
retaining employees to training new
hires, safety practices, workplace poli-
cies and employee benefits. FC
Flow Control
 Connect
SOLUTIONS FOR FLUID MOVEMENT, MEASUREMENT & CONTAINMENT

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Flowrox .......................................................................................... 7 Sage Metering .............................................................................. 19

Fox Thermal ................................................................................. 22 Spitzer and Boyes LLC .................................................................. 24

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 Featured
content

FlowControlNetwork.com

@FLOWCONTROL_MAG
Courtesy of ABB

Case study: Condition

#monitoring systems provide
early leak detection and
allow users to optimize their
heat-transfer #pumps. Failure to protect the replacement motor from dirt and water
ow.ly/JJqr50tV4Pd
ingress to the same degree as the original motor may result
in bearing contamination and early failure or damage to the
#ApplicationCorner: The electrical windings or connections.
heating value of actual
#naturalgas at a given –Tyler Lensing and George Weihrauch, ABB
location could be different
from a typical NAESB
natural gas heating value by
Courtesy of David M. Schmitt

as much as a few percent.

ow.ly/Uest50t9bXD WHAT'S ON FACEBOOK

Consider components and

features when selecting the
correct #pipeline ball #valve
for isolation, control, general
service and severe service Functionality and seating
applications | @FisherValves technology for floating
ow.ly/g9YH50rjVz2 ball valves
A typical floating ball valve
Rotating buoyancy modules seals off the line pressure
can help manage and mitigate using soft seats.
risks associated with buckling
bit.ly/2LvI1T4
of high-temperature
subsea pipelines.
ow.ly/MUnJ50pxbdG
@TrelleborgGroup
Facebook Twitter LinkedIn
facebook.com/flowcontrolmagazine @flowcontrol_mag linkedin.com/groups/4068011/profile

32 | June 2019
 Do you have
instant visibility
into your flow
meter health
across your
entire plant?

The PlantwebTM Insight Coriolis application

allows you to reduce manual inspections of
your Micro MotionTM Coriolis meters by
providing continuous, consistent, reliable and
actionable asset data, uploaded to an easy to
read dashboard.
• Meter health in real-time
See which meters have issues and what actions
are needed before you go into the field
• Status at a glance
Instantly see the status of your meters on one
PLANTWEBTM INSIGHT
CORIOLIS APPLICATION
dashboard including Smart Meter Verification
results Continuous monitoring of
your Coriolis meters helps
• Proactive servicing identify problems in real-time
Better prioritize maintenance and avoid and provides instant access to
potential safety hazards actionable diagnostics.

For product information:

www.Emerson.com/Plantweb-Insight

The Emerson logo is a trademark and service mark of Emerson Electric Co. ©2019 Emerson Electric Co.