Boilers

& Steam
Generators
Considerations for fluid flow
in power generation equipment

Also Inside

Instrumentation to help transition

to a digital-enabled plant

Flat-plate valve technology

and laminar flow

Predicting sealing performance

with texture analysis software

NOVEMBER 2019 • Vol. XXV, No. 11

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

FC_0119_Cover.indd 1 12/14/18 8:24 AM

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SOLUTIONS FOR FLUID MOVEMENT, MEASUREMENT & CONTAINMENT

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MAY 2018 • Vol. XXIV, No. 5

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Table of Contents | November 2019 • Vol. XXV, No. 11

Cover Story
10 The flow of fluids in boilers and
steam generators
By Amin Almasi
Practical guidelines are presented for a range
of boilers and steam generators — from small,
simple boilers to large, complex multisection
steam generators for large industrial facilities.

Features
13 Using digital instrumentation to
10
transition to a digital-enabled plant
By David Lincoln, ABB Measurement & Analytics
When it comes to instrumentation, digital’s benefits
over older analog-based units make it the logical
choice for process engineers seeking to improve the
efficiency and controllability of their plant.

17 Moving beyond basic temperature

measurement instrumentation to
improve performance and reduce costs
13 17
By Ryan Leino, Emerson
Tools are available to get more from a temperature
reading than just a process variable, which can simplify
installations and deliver more reliable readings.
Departments
4 From the Editor
21 Laminar flow valves realized:
The flat-plate technology
By R. Barth Strempek and Thomas Christensen
6 News & Notes
This flat-plate valve technology and its operational
characteristics including laminar flow and faster fluid 8 Application Corner & Quiz Corner
speed have the potential to change the fluid control
landscape, improve efficiencies and enhance processes. 29 Product Focus

25 Predicting sealing quality by filtering 31 Advertiser Index

surface texture data
By Mark Malburg, Digital Metrology Solutions 32 FlowControlNetwork.com
Modern texture analysis software can predict sealing
performance and address root causes of potential leakage. Cover: Vithun Khamsong/iStock

Subscription Information
Flow Control (ISSN #ISSN 2641-6735) is published 12 times a © Endeavor Business Media, 2019. No portion of this publica-
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A controlled circulation publication, Flow Control is distributed
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2 | November 2019 Flow Control

 kJ

kWh
ft/s lb/h
ft3/h
Sft3/h

fact
Steam mass flow and enthalpy measurement
OPTISONIC 8300 –
technology driven by KROHNE
• Inline superheated steam ultrasonic flowmeter for boiler and power plant monitoring
or steam billing

• Flow velocity range –200 to +200 ft./s (–60 to +60 m/s)

• No measurement drift, recalibration or maintenance needed for years

• Sizes 2 to 24“ (DN50-600) rated to 2900 psi (200 bar), –13 to 1004 °F (–25...+540 °C),
higher ratings on request

• P/T inputs, meter and process diagnostics, optional integrated flow computer

products solutions services

More facts about the OPTISONIC 8300: www.us.krohne.com/optisonic8300

 From the Editor
VICE PRESIDENT & GROUP PUBLISHER
MICHAEL C. CHRISTIAN
mchristian@endeavorbusinessmedia.com
ASSOCIATE PUBLISHER

L
ast month, I had the opportunity to Our cover story this issue is an article JIM SEMPLE | 908-963-3008
jsemple@endeavorbusinessmedia.com
attend the 2019 Emerson Global from Amin Almasi, who talks about practi-
Users Exchange in Nashville. As a cal guidelines for a range of boilers and EDITOR IN CHIEF
MOLLY ROGERS
first-time attendee, I enjoyed seeing the steam generators and the flow of fluids.
mrogers@endeavorbusinessmedia.com
wealth of resources, sessions, presenta- Next, David Lincoln with ABB discusses
CONTRIBUTING EDITORS
tions and solutions for attendees. In the the capabilities of digital instrumentation
JESSE OSBORNE
opening session, Lal Karsanbhai, execu- and offers tips on how to make the transi- josborne@endeavorbusinessmedia.com
tive president of Emerson Automation tion to a digital-enabled plant. MARIE MCBURNETT
Solutions, spoke about dynamic industry You’ll also find an article from mmcburnett@endeavorbusinessmedia.com
trends in oil and gas, power genera- Emerson’s Ryan Leino, who compares GROUP ASSISTANT EDITOR
tion, life sciences and food and bever- two approaches to a temperature mea- DANIEL GADDY
age processing, as well surement instrumenta- dgaddy@endeavorbusinessmedia.com

as Emerson’s strategic tion installation. The COLUMNIST

acquisitions and a suite first illustrates tradi- DAVID W. SPITZER

ART DIRECTOR
of technology solutions tional best practices
RYAN CARLSON
to help companies with with basic components.
PRODUCTION MANAGER
their digital strategies. The second uses more
AMANDA PORTER
Then, Karsanbhai invited advanced components aporter@endeavorbusinessmedia.com
Peter Zornio, chief tech- and design techniques DISTRICT MANAGER
nology officer, and Stuart for a safer installation JAY HAAS | 281-980-5831
Harris, group president of with a higher degree of jhaas@endeavorbusinessmedia.com
Emerson’s newly formed accuracy, greater reli- ACCOUNTS MANAGER
Digital Transformation Emerson Global Users Exchange at the ability and lower life- MARK MALLOY | 224-234-8275

business, to the stage Gaylord Opryland Convention Center, cycle costs. mmalloy@endeavorbusinessmedia.com
Nashville. Courtesy of FC Staff
for a chat about digital Also in this issue, ACCOUNTS MANAGER
LISA WILLIMAN | 518-322-6691
transformation (the theme of the event), authors R. Barth Strempek and Thomas
lwilliman@endeavorbusinessmedia.com
its challenges and opportunities. Christensen explain flat-plat valve tech-
MARKETING MANAGER
For attendees, the event offered road- nology and its operational characteristics
SARAH DE VOS
map sessions and breakout industry including laminar flow and faster fluid
DIGITAL PRODUCT DIRECTOR
forums with experts from the chemicals, speed. Lastly, Mark Malburg with Digital NICK PHILLIPS
engineering, life sciences and pharma- Metrology Solutions shows how modern DIGITAL OPERATIONS MANAGER
ceuticals, mining, oil and gas, power, pulp texture analysis software can predict seal- MARY BETH ROMANO
and paper, and refining and petrochemi- ing performance and address root causes AUDIENCE DEVELOPMENT MANAGER
cal industries. Technology roundtables and of potential leakage. ANNA HICKS
educational services offered one-on-one I hope you enjoy reading this issue of SUBSCRIPTION & REPRINT REQUEST
conversations with Emerson’s representa- Flow Control. flowcontrol@omeda.com

tives, and in the afternoons, the technol-

CORPORATE TEAM
ogy exhibit opened its doors with booths
CHIEF EXECUTIVE OFFICER
displaying Emerson’s latest solutions. CHRIS FERRELL
During the event, Emerson made several Molly Rogers CHIEF OPERATING OFFICER
company announcements, and you can read mrogers@endeavorbusinessmedia.com PATRICK RAINS
more about them on page 6 of this issue. @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: KRE Consulting | Jesse Yoder, Ph.D.: Flow Research

4 | November 2019 Flow Control

News & Notes

Company news including Emerson’s Location Awareness allow Waukesha Bearings and Cook
and wireless video. These applications Compression to validate designs and
Emerson spotlights digital enhance personnel safety practices, analytical methods and test products
transformation at annual improve plant security and help ensure under demanding operating conditions.
users exchange environmental compliance. A reliable In addition, they equip R&D engineers to
At the 2019 Emerson Global User and fast connection between devices develop new application solutions. The
Exchange, Emerson made several and people streamlines decision mak- Innovation Lab capabilities will include
announcements, beginning with the intro- ing by providing real-time analytics. It also performance testing of journal and thrust
duction of its new Digital Transformation enables a mobile workforce to virtually bearings with oil or process lubrication
business, which provides resources to come together, collaborate and resolve over a wide range of loads and speeds;
help manufacturers develop and imple- critical issues in a timely manner. The new damper design characterization and
ment pragmatic digital transformation wireless access point supports mobile enhancement; performance and accel-
strategies. The $650+ million business applications that offer instant access erated life-cycle testing of reciprocating
combines existing expertise in consulting, to process control data, maintenance compressor components; flow charac-
project execution, smart sensor technolo- information and operation procedures, terization of compressor valves; dynamic
gies, data management and analytics. enabling improved plant productivity and testing of packing case leakage; competi-
The organization will help customers not worker safety. tive benchmarking; and advanced materi-
only establish a clear vision for digital Emerson has also enhanced its Plantweb als development. The Innovation Lab is
transformation, but also execute with con- digital ecosystem, a comprehensive scheduled for completion in the second
fidence and realize measurable results at operational analytics portfolio, delivering quarter of 2020, with test rig commis-
each step of their journey. Stuart Harris actionable insights to address industrial sioning to follow.
was named group president for Emerson’s manufacturers’ operational challenges.
new Digital Transformation business, Operational analytics with embedded New app calculates
which brings together existing and new domain knowledge can improve perfor- hydraulic oil viscosity
Emerson resources. mance of simple equipment, complex at different pressures
Emerson also announced that it is assets and process units, as well as entire Webtec launched a new online hydraulic
partnering with Cisco to introduce a production plants. Additionally, Emerson’s oil viscosity calculator app that calculates
next-generation industrial wireless net- enhanced portfolio includes machine the viscosity of hydraulic oil at different
working solution that transforms data learning and artificial intelligence that can operating pressures. Hydraulic fluid sup-
management to improve plant produc- be used to identify new discoveries and pliers provide oils with different viscosi-
tivity, reliability and safety. The new deepen insight to improve business perfor- ties. These oils are most-often badged
Emerson Wireless 1410S Gateway with mance. Emerson’s portfolio now provides in terms of their ISO number or grade,
the Cisco Catalyst IW6300 Heavy Duty both prepackaged analytics solutions as where common grades for hydraulic cir-
Series Access Point combines the lat- well as a complete analytics toolbox for cuits include ISO 32, 46 and 68. Using
est in wireless technology with advanced users to develop their own applications. Webtec’s app, engineers select the oil
WirelessHART sensor technology, deliv- This portfolio is supported by Emerson’s being used, along with the system tem-
ering reliable, secure data, even in the Operational Certainty consulting practice perature (°C) and pressure (bar), hit the
harshest industrial environments. To and data management capabilities. submit button and the viscosity (cSt) pops
help enable new digital transformation up in the window. To see the effects on
strategies, this industrial networking Dover breaks ground on viscosity of fluctuations in temperature
solution combines Emerson’s expertise Houston Innovation Lab or pressure, the user alters the values in
in industrial automation and applications Dover Precision Components is breaking these fields accordingly. The free Webtec
with Cisco’s innovations in networking, ground on a new Innovation Lab. The app is the company’s light version. More
cybersecurity and IT infrastructure. Driven nearly 12,000-square-foot building detailed results, including graphs (some
by the demand for greater productivity, is being constructed directly north of in 3D), can be accessed by logging in
lower maintenance costs and improved the company’s Pearland operations in (existing users) or registering (new users).
worker safety, industrial manufacturers Houston, Texas. Representing the com- The graphs can be saved for use in the
are accelerating investment in robust IoT pany’s ongoing commitment to research user’s own reports.
sensor networks combined with scalable and development, the Innovation Lab
operational analytics tools to improve will centralize test rigs for hydrodynamic Eaton collaborates with
organizational collaboration and decision- fluid film bearings and reciprocating San Jacinto College
making. This next-gen wireless access compressor components previously Eaton contributed more than $2 million
point provides enhanced Wi-Fi bandwidth housed in Pewaukee, Wisconsin, and to help San Jacinto College (San Jac) in
necessary for real-time safety monitoring, Knoxville, Tennessee. These test rigs Houston, Texas, establish its new Center

6 | November 2019 Flow Control

for Petrochemical, Energy, & Technology pressures up to 140 bar, the AMF doubles Endress+Hauser and Vector
(CPET). Eaton’s consulting, electrical previous test facility capabilities to meet CAG secure MIV contract at
design services and equipment dona- industry measurement challenges. The Texas refinery
tions helped San Jac create a hands-on AMF has high flow rates for both gas Endress+Hauser secures the Main
environment and curriculum for students and liquid within one multiphase facility. Instrument Vendor (MIV) contract at a
to study complex energy technologies Spanning 1,600 m2, the AMF contains a large Texas refinery. Endress+Hauser and
and ultimately enter the regional work- £1.45 million, full-production scale sepa- its representative, Vector Controls and
force better prepared for success. In rator with an operating weight of 270 Automation Group (CAG), will support the
support of San Jac’s energy industry tons, offers an integrated subsea choke refinery’s project. Endress+Hauser defines
program, Eaton designed and equipped and is capable of testing the complete MIV services as a contract placed with a
the electrical labs and power system at range of flowmeters. 2D, three-phase, single instrumentation specialist partner
the facility’s glycol plant. Additionally, San x-ray tomography and sensors deliver to provide a total solution for a project
Jac students will have ongoing access to high-definition images of complex flows to including valves. From feed to operation,
Eaton experts and the Eaton Experience expand industry’s understanding of fluid customers can save time, reduce cost and
Center in Houston for supplementary behaviors and their effect on measure- mitigate risk with one partner to ensure
hands-on training in electrical systems ment. The AMF will focus predominantly consistency and avoid ambiguities. As the
powering petrochemical operations. on the global subsea sector and wet gas industry implements IMO 2020 regulations,
Eaton’s collaboration with San Jac is part business, facilitating company-led indus- expansions such as these help refiners add
of a long-term, multipronged effort to trial projects and product development, capacity to meet the needs of the indus-
provide education, training and industry hands-on industry training and academic try. IMO 2020’s proposed regulations aim
programs for current and next generation research. Scottish Enterprise supported to reduce sulfur content in fuel of marine
electrical industry leaders. Eaton’s new the development of the AMF with £4.9 vessels and limit future greenhouse gas
vice president of the oil and gas seg- million of research and development emissions. Endress+Hauser and Vector
ment for its Electrical business, Vinay funding. TÜV SÜD National Engineering CAG will closely support the project timeline
Varma, and his team are working with Laboratory’s parent company, TÜV SÜD to help the refinery maximize its potential.
customers to tailor Eaton solutions to AG, invested £11.1 million. Project services will include: project man-
meet their project, maintenance, repair agement, embedded engineering, Smart
and service needs. Tsurumi Pump celebrates Plant Integration (SPI), quotation, reporting,
company milestone procurement, expediting and prioritization,
Siemens offers technical Tsurumi Pump is celebrating 40 years of documentation, warehouse support with
training with digital academy business in the U.S. The pump manu- receiving, inspection, tagging and shipping,
Siemens’ SITRAIN Digital Industry facturer has seen growth since opening and on-site construction coordination. FC
Academy offers technical training exper- a location in Chicago, Illinois, 40 years
tise needed to advance knowledge and ago. Tsurumi Pump will be marking the
Upcoming events
sharpen skills. Certified instructors with milestone with a yearlong celebration
an understanding of equipment can help and has plans to further grow its busi-
make decisions in the daily operation ness in the market, including expanding POWERGEN
New Orleans
of a plant’s automation and drive sys- the facility in Salt Lake City, Utah, to a
Nov. 19–21
tems. SITRAIN offers a variety of learn- 37,000-square-foot warehouse, to better
powergen.com
ing options designed to meet training service customers in the western U.S. The
needs — from novice to expert. It has company is also in the planning stages of Rockwell Automation Fair
over 45 training locations nationwide. a philanthropic initiative to provide sup- Chicago
Classroom learning offers course materi- port to the American market. It will focus Nov. 20–21
als and hands-on experience at one of on education, training and knowledge rockwellautomation.com
Siemens’ training locations or on-site. exchange in the engineering and pump
Digital learning has flexible online and technology areas. Another company ini- AHR Expo
virtual learning solutions. tiative enables employees to donate time Orlando
during business hours to philanthropic Feb. 3–5, 2020
ahrexpo.com
TÜV SÜD National community work, as well as hosting com-
Engineering Laboratory pany events that encourage employees to
launches multiphase facility volunteer on service projects centered on
Send news and events for consideration
TÜV SÜD National Engineering Laboratory helping the environment. Tsurumi Pump
to Molly Rogers at mrogers@
launched its £16 million Advanced is a subsidiary of Tsurumi Manufacturing
endeavorbusinessmedia.com.
Multiphase Facility (AMF). Operating at Company, based in Osaka, Japan.

www.flowcontrolnetwork.com November 2019 | 7

 Application Corner
By David W. Spitzer

Natural gas flow measurement:

Energy flow matters

P
revious columns discussed that the Online or laboratory composition analyzers
composition of natural gas can and/or calorimeters can be used to correct
and does vary over time and at for the actual natural gas composition
different locations, and its composition when the measurement of energy flow
may be significantly different than typi- is important. Laboratory analysis can be
cal North American Energy Standards used to periodically reconfigure and/or
Board (NAESB) natural gas. As a result, recalibrate some flowmeters to account
the energy content, density and thermal for the latest natural gas compositions.
properties of the flowing natural gas can Coriolis mass, differential pressure flow-
also be different. Density and thermal meters, positive displacement, thermal,
properties can affect the performance of turbine and vortex shedding flowmeter
some flowmeters. However, energy con- technologies are often used to measure
tent variations can affect all flowmeters the flow of natural gas. Next month, I will
intended to measure the flow of energy examine how each of these technologies
— even when the flowmeter produces can be affected by changes in natural gas
measurements that accurately reflect the composition. FC
flow of natural gas.
Working backwards, if one assumes David W. Spitzer is a principal at Spitzer
that a given natural gas flowmeter accu- and Boyes, LLC, which offers engineer-
rately measures flow, the energy flow will ing, focused market research, writing/
vary directly with the energy content of the editing white papers, strategic market-
flowing natural gas because the energy ing consulting, distribution consulting,
content of the flowing natural gas can be seminars and expert witness services
significantly different than typical NAESB for manufacturing and automation com-
natural gas. panies. Spitzer has written more than
With that said, the energy content could 400 technical articles and 10 books
be more accurately determined using about flow measurement, instrumen-
the actual (measured) energy content tation and process control. He can
to improve measurement of the amount be reached at 845-623-1830 or via
of energy flowing through the flowmeter. spitzerandboyes.com.

8 | November 2019 Flow Control

 Quiz Corner Where and how should a differential pressure
flow transmitter be located for gas service?
A. Above the flow element with the impulse tubes sloping upward to the transmitter
B. Above the flow element with the impulse tubes sloping upward then downward to the transmitter
C. Below the flow element with the impulse tubes sloping upward then downward to the transmitter
D. Below the flow element with the impulse tubes sloping downward to the transmitter

A
ccurately transmitting the differential pressure gener- Additional complicating factors
ated by the flow element to the transmitter involves In some installations, it is not possible to install impulse
keeping the impulse tubing full of gas. Locating the tubes that constantly slope upward to the transmitter, so
transmitter below the flow element enables any liquid present other means may be used to effect accurate transmission
to accumulate and potentially adversely affect accurate signal of the differential pressure signal. These include diaphragm
Pobytov/iStock

transmission of the differential pressure signal, eliminating seals or pots where liquid can accumulate without affecting
Answers C and D. The downward sloping impulse tubing also the measurement.
eliminates Answer B. Thus, Answer A is correct.

www.flowcontrolnetwork.com November 2019 | 9

Cover Story: Power Generation

The flow of fluids in

boilers and steam generators
Practical guidelines are presented for a range of boilers and steam
generators — from small, simple boilers to large, complex multisection
steam generators for large industrial facilities.
By Amin Almasi

S
team is important in many plants furnace section of the boiler, the faster the is not suitable, nor acceptable, in many
and facilities, and it is widely used steam production. Any remaining heat in cases. High velocities of hot gases can
in applications including industrial the combustion gases can then either be be problematic, as associated erosion or
heating, heat tracing, steam turbine drivers, evacuated or made to pass through an corrosion effects are damaging. As an
steam cleaning, process usage, atomiza- economizer; the role of which is to warm indication, the gas velocity through the
tion using steam, cleaning, moisturization boiler feedwater before it reaches the boiler. boiler passes should usually be less than
and humidification. A boiler or steam gen- Superheated steam is needed in many 14 m/s. However, the velocity is often
erator is a device used to produce steam applications and plants. The advantage of more than this value.
by applying heat energy to water. strong, superheated steam is that more Burners should be provided so that no
This article discusses boilers and steam work can be done by smaller volumes of flame impingement on the boiler’s walls
generators and the flow of fluids in them. steam. This enables all the components, would occur when firing the specified fuel
Useful guidelines are provided for a wide piping, devices and equipment to be under all operating conditions. Emissions
range of boilers and steam generators — reduced in size, and steam turbines and are a major problem in boilers. The firing
from small, simple boilers to large, complex steam consumers can be better adapted system should be equipped with advanced
multisection steam generators for large to installations and applications. low emission and low NOx burners.
industrial facilities.
Combustion Air flow to boilers
Boilers and steam generators The furnace section of a boiler should be To create optimum burning characteristics
A boiler incorporates a firebox or furnace in sufficient in size for flame development of the fire, air should be supplied to the
order to burn the fuel and generate heat. and should allow complete and efficient
The generated heat is transferred to water to combustion of the fuel before leaving the
make steam — the process of boiling. This furnace. The furnace section should pref-
produces steam at a rate that varies accord- erably be a single compartment. Central
ing to boiler operation. High-quality treated wall or division walls on a furnace section
water known as boiler feedwater should be
used to produce steam. Pressurized boiler
feedwater is pumped to boilers or steam
generation systems using boiler feedwater
pumps. The higher the temperature of the
Thossaphol/iStock

10 | November 2019 Flow Control

fire. Most boilers depend on a mechanical many sections such as the evaporator, and sometimes have fins to maximize the
draft equipment (fan) rather than natu- economizer and superheater. surface area. However, the application of
ral draft. This is because natural draft A simple way to rapidly produce steam is finned tubes in any type of boiler or boiler
is subject to outside air conditions and to feed boiler feedwater under pressure into section needs care. This type of simple boiler
temperature of flue gases leaving the fur- tubes surrounded by the hot combustion is generally preferred in medium-pressure,
nace. These factors make effective draft gases. This simple concept is used in many small-size applications, since the medium-
hard to obtain and control. Therefore, the inexpensive, small and basic boilers that are pressure water/steam is contained within
mechanical draft equipment/fan is more ultra-compact and lightweight. The tubes narrow pipes, which can contain the pres-
economical and preferable. frequently have a large number of bends sure with a relatively thinner wall.
There are three types of mechanical
draft: induced draft, forced draft and
balanced draft. Induced draft can be
obtained by various methods. The most
common method is by using an induced
draft (ID) fan, which sucks flue gases out
of the furnace and up the stack. Almost
all induced draft furnaces have a negative
pressure. Other types of induced draft
are stack effect, steam jet and ejector-
oriented, which are used in small, special-
ized applications.
Forced draft is obtained by forcing air
into the furnace by means of a forced-
draft (FD) fan and ductwork. Air is often
passed through an air heater. It heats
the air going into the furnace in order
to increase the overall efficiency of the
boiler. Dampers are usually used to con-
trol the quantity of air admitted to the
furnace. Forced-draft furnaces most
often have a positive pressure. Balanced
draft is obtained through the use of both
induced and forced draft. This is more
common with larger boilers where the flue
gases must travel a long distance through
many boiler passes. The induced-draft fan
works in conjunction with the forced-draft
fan, allowing the furnace pressure to be
maintained slightly below atmospheric. Gorman-Rupp Super T Series® pumps deliver reliable
performance in harsh solids-handling water applications.
Add a Gorman-Rupp Eradicator ® Solids Management
Steam generation and System to clean up mop strings, flushable wipes, gloves
steam flow and more. Unlike cheap imitators, Super T Series pumps
The goal in a boiler is to make the heat deliver years of trouble-free operation backed by a five-year
flow as efficiently as possible from the warranty and the industry’s fastest parts service.

heat source to the water to gener-

For more information, contact your
ate steam. The water is confined in a nearest Gorman-Rupp distributor
restricted space heated by the fire. The or visit GRpumps.com.
produced steam has a lower density than
the water and therefore will accumulate
at the highest level in the boiler.
There are different configurations for GRpumps.com | © 2019 The Gorman-Rupp Company 565

boilers. Simple, straightforward models

use one-section boilers or a once-through
concept. Other boilers are complex with

www.flowcontrolnetwork.com November 2019 | 11

 Once-through-type boilers are also above the saturation temperature. The allow for uniform steam temperature dis-
used in many applications. They usu- use of superheated steam allows higher tribution in the elements and tubes of
ally consist of a continuous tube or coil. steam cycle efficiency and better opera- the boiler to prevent overheating of tubes
There are many models of once-through tion. As the fire is burning at a much and headers. For example, in large boil-
boilers in different sizes from small to higher temperature than the saturated ers, sufficient thermocouples on outlet
large. Water is usually pumped into the steam it produces, far more heat can tube legs and other locations should be
tube/piping system at the bottom, and be transferred to the once-formed steam provided for monitoring the steam tem-
the steam is drawn off at the top. Water by superheating it and turning the sus- perature distribution.
enters the bottom of this tube/piping at a pended water droplets into more steam, The design/configuration of a boiler and
high pressure and high velocity. In some thus greatly reducing water consumption its control and monitoring systems should
specialized boilers, the water velocity can in the steam system. ensure that the various sections of the
be as high as 100 m/s or more. As the hot There are many models for the super- boiler, such as superheaters, will not over-
gases pass between the coils/tubes, they heating sections of boilers. A common heat during all possible cases of opera-
gradually cool, and the heat is absorbed concept for large boilers is that the steam tion, transient cases, start-up, shutdown,
by boiler feedwater. superheating piping (or coils) is directed loss of steam temperature control, boiler
through the flue gas path in the boiler trip, sudden load rejection and restoration
Evaporator furnace. As a rough indication for large to full load.
An evaporator is one of the important boilers, the temperature of this area is Measures should be taken to avoid
sections in a multisection boiler. Different usually between 1200°C and 1600°C. unbalanced temperature distribution,
configurations for evaporator sections are Some superheaters are radiant type, which can be a major problem in large boil-
available. Evaporators of a large boiler others are convection type, and most ers, in all sections and dimensions, such
are usually spirally arranged water walls of them are a combination of the two. as across the boiler width. Temperature
with smooth tubes in the flame region While the temperature of the steam in measurements are also needed to moni-
and vertical smooth tubes in the upper the superheater is raised, the pressure of tor and control temperature distribution
part of the radiation zone. The furnace the steam typically stays constant. Most across all sections. For some large boilers,
of such large boilers is usually a water- importantly, the process of superheat- 100 thermocouples or more are needed
cooled radiant-type, with welded gas- ing steam is to remove all water droplets to properly measure temperature in many
tight membrane wall construction, and entrained in the steam to prevent damage different locations and ensure even and
arranged to minimize the adverse effects to the steam system, associated steam balanced temperature distribution. FC
of firing, such as slagging, on the boiler. piping, steam users and particularly
Pressure parts of boilers should be steam turbine blading.
provided to withstand actual pressure and Amin Almasi is a lead
pressure rise margins, including internal Monitoring and uniform mechanical engineer in
pressure drops and others. In addition, temperature profile Australia. He is chartered
the tube and piping materials for boilers In small boilers and applications, relatively professional engineer of Engineers
should be generously selected with regard simple concepts are used for operation, Australia (MIEAust CPEng – Mechanical)
to corrosion and erosion. All boiler head- control and monitoring. Larger boilers and IMechE (CEng MIMechE) in addi-
ers, piping and tubes are usually made need sophisticated concepts, tools, logics tion to a M.Sc. and B.Sc. in mechani-
of seamless steel alloy piping or tubes and various sensors and actuators. Dry cal engineering and RPEQ (Registered
(from suitable alloy steels). Consideration operation and localized high temperatures Professional Engineer in Queensland).
is needed for the material of tubes/pip- can cause problems in boilers. In many He specializes in mechanical equipment
ing, arrangement of tubes/pipes and flow small boilers, the fire will automatically and machineries including centrifugal,
velocities in the tubes/pipes, as well as cut off by temperature or pressure, so screw and reciprocating compressors,
provisions to prevent high-temperature if the boiler becomes completely dry, it gas turbines, steam turbines, engines,
steam corrosion and steam oxidation of would be impossible to damage the coils/ pumps, condition monitoring, reliability,
tubes. Adequate provisions and spacing tubes, as the fire would be cut off by the as well as fire protection, power genera-
should be made for thermal expansion control and monitoring system. Larger, tion, water treatment, material handling
of piping, tubes and headers. Tubes and multisection boilers need more sophis- and others. Almasi is an active member
steam piping should be widely spaced to ticated logics and concepts for proper of Engineers Australia, IMechE, ASME,
prevent bridging by combustion products operation and control. and SPE. He has authored more than
such as soot or ashes. Monitoring plays a major role in opera- 150 papers and articles dealing with
tion, safety and reliability of boilers. All rotating equipment, condition monitor-
Superheater critical parameters at all strategic loca- ing, fire protection, power generation,
Continued heating of the saturated steam tions should be monitored. The design water treatment, material handling and
brings the steam to a superheated state, and configuration of all sections, such reliability. He can be reached at amin.
where the steam is heated to a temperature as evaporators and superheaters, should almasi@ymail.com.

12 | November 2019 Flow Control

Features: Instrumentation

Using digital instrumentation to

transition to a digital-enabled plant
When it comes to instrumentation, digital’s benefits over older
analog-based units make it the logical choice for process engineers
seeking to improve the efficiency and controllability of their plant.
By David Lincoln, ABB Measurement & Analytics

W
ith the world increasingly going
digital, it is no surprise that
industry is rapidly adopting
this game-changing technology. As the
frontline of any industrial process, instru-
mentation provides an invaluable starting
point for gauging performance, safety and
compliance, as well as identifying areas
for potential improvements.
Offering greater accuracy, range and
depth of information, digital technology
can provide operators and process engi-
neers with a timely and detailed picture of
both operating conditions and the status
of their measurement equipment. This
article looks at the benefits delivered by
the latest generation of digital instru-
ments and explains how to make the
transition to a digital-enabled plant.
Most instruments make a measure-
ment, amplify it, convert it and then
transmit it. Because data is sent as a
stream of discrete ones and zeros, a
digital instrument will always provide
an accurate representation of process
values. By contrast, analog instruments
represent data through a varying electrical
signal. One of the problems with this is
scaling, whereby a mismatch can occur
between the transmitting range of an
instrument and the input scaling range Diagnostic data allows engineers to
quickly spot faults and ensure they are
of the receiving instrument. This can properly equipped with the knowledge
create incorrect readings, as well as send and parts needed to fix them.
operators looking for measurements that All images courtesy of
are unaccounted for. ABB Measurement & Analytics

www.flowcontrolnetwork.com November 2019 | 13

 Another advantage of digital is the abil-
ity to combine multiple different values
into the signal. Unlike analog methods,
which can only send one signal at a time,
digital allows additional measurements
to be sent along with the primary mea-
surement, such as density, temperature
or pressure.
Examples include chemical analyzers
Dynamic QR codes are among
and level detectors that can also provide the everyday technologies used
temperature sensing, helping operators for industrial applications.
make better process control decisions.
ABB’s digital transmitters feature a choice of
Flowmeters that measure conductivity in Digital diagnostics digital communication options.
the pipe can detect changes that flag Digital instrumentation also makes life
issues such as increasing contamina- easier when things go wrong or processes Many modern instruments offer remote
tion, highlighting the potential need for stray from their limits. Before digital access to diagnostics and configuration
a change in chemical dosing to counteract instruments were available, the most changes. This means, if there are any
it. Air bubbles caused by pump cavita- an operator could hope for to indicate problems with power management or a
tion can also be detected by flowmeters, a problem was a fault warning light or a sensor element or cable is broken, exact
indicating that preventive maintenance reading that was out of the ordinary. On information on the time of the event and the
is required. a 4-20 mA device, for example, a low or exact location of the affected device can
Ease of use is another benefit of digital high current signal outside of the normal be obtained — either locally at the device
instruments. Unlike analog meters, which range would indicate a problem but would itself or by relaying the data to a centralized
can be difficult to interpret quickly and not necessarily provide the detail needed control system. This cuts maintenance time
accurately, digital information can be to pinpoint its root cause. and costs, as engineers are only deployed
presented on large touch-screen dis- Digital fills this gap. Depending on the as needed, and ensures that any prob-
plays, enabling operators to drill down solution used — whether it is adding lems in the process being measured are
for further information if necessary. HART to a 4-20 mA device or opting resolved before they can escalate.
Smartphones and tablets can also be for a fully digitized system — it is now Trends and process histories are also
used to remotely interact with plant possible to obtain in-depth information much easier to access and analyze when
equipment and display analytical data, on instrument performance, including they are based on a stream of easily
which is particularly useful when an any factors that are causing a device storable and accessible data that can
instrument is situated in a hard-to-reach to deviate from its normal calibrated be analyzed and interpreted and turned
location or when engineering resources settings or that might be causing faulty into readily interpretable graphical for-
are at a premium. measurement signals. mats. Engineers can see the precise time

14 | November 2019 Flow Control

 Many vendors now offer condition
monitoring tools that confirm the health
of measurement devices and stream-
line their servicing. Features such as
automated testing of devices improves
the quality and consistency of measure-
ments, giving better results, while the
ability to relay data to a manufacturer’s
service experts can help ensure high
availability and reliability of equipment,
Coupling digital technology with easy installation allows instruments to be installed widely across process plants. low unplanned downtime and reduced
operating and maintenance costs.
that an event occurred, as well as how example of this is the use of QR codes to When used to their full extent, the
changes in parameters may have led to it. display device maintenance and operating expanded capabilities offered by digital
This also helps with the shortage of conditions. By scanning the QR code with instruments can enable maintenance
skilled operators. Process instrumentation a smartphone, an engineer can relay data regimes to shift from a time-based to
that can provide analysis as well as detailed about the instrument to its manufacturer, condition-based frequency, with parts
readings can help young or inexperienced who can offer remote assistance. being replaced as necessary, according
plant personnel who may not have the The concept of remote support is being to their effect on performance.
skills of their more experienced colleagues. taken to new heights by forward-thinking Furthermore, by guarding against the
In many cases, technologies used in every- instrumentation vendors using the power risk of faulty measurement or non-
day life are being used for industrial pur- of digitalization to maximize the uptime availability caused by a malfunction,
poses, offering a familiar interface. One of their equipment. it is also possible to protect against

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potential penalties caused by noncompli- Building a plant’s point for organizations that want more
ance with regulatory requirements around digital future from their instruments without a complete
areas such as safety or discharges to Many companies are daunted by the idea upgrade to a digital system.
the environment. of digitalizing their factory or plant. But In assessing which processes to digi-
it does not need to be an expensive “big tize, look at existing procedures and pro-
Taking the wider view bang” project that transforms the com- cesses that are used to record data for
Although digital instrumentation brings pany in one go. A good place to start is that process. Do they generate a lot of
great benefits to the management and by considering single processes that can manual paperwork? What data is recorded,
monitoring of individual machines or be easily digitized or connected and can and could it be done more automatically?
items in process plants, it offers even bring immediate benefits. What data is useful, and which is recorded
greater advantages if seen as part of a First, look for ways of getting more from routinely but to little effect?
more strategic, companywide process of the instruments already installed on the Get managers and process staff on
digitalization. The rise of web-connected site. In many cases, operators tend to board and find out what data they need,
devices allows companies to benchmark purchase instruments for their primary where the issues are, or how they could
their various facilities against each other purpose without realizing the raft of use more detailed data or more insight
to tease out best practice. into process behavior to solve
In this way, data can be used specific problems.
not only to maximize pro- This does not need to have
cess performance but also to a big impact on the site’s IT
address other key areas, includ- department. Adopting scalable,
ing improving customer satis- cloud-based data management
faction, determining the most systems that meet the needs
effective allocation of capital of the application can avoid
and enabling better decision- tying up internal IT resources
making to improve day-to-day or personnel.
business, financial and opera- Cloud-based infrastructure
tional activities. helps people and systems access
With the growing capabili- the data they need. The data
ties of artificial intelligence can come from inputs from pro-
and machine learning, the cess-line instrumentation and
traditional challenge of data — signals directed to a variety of
how it is analyzed, processed control equipment — program-
and shared — is also increas- mable logic controller (PLC),
ingly addressed. The wealth of supervisory control and data
data produced by digital and acquisition (SCADA), and dis-
connected instruments across tributed control systems (DCS).
a company can be collected
and analyzed by software solu- Conclusion
ABB’s RVG200 touch-screen paperless data recorder provides quick
tions that share inputs from access to a wide variety of process data. Digitalization needs to be part
sensors, analyzers and control of a culture of continuous
systems. The result is a better over- additional data that can be extracted. improvement, taking staff suggestions
all view of what is happening, helping An example is Coriolis flowmeters. In addi- of how processes could be digitized and
operations achieve tighter integration tion to measuring flow, these flowmeters linked to provide better, more timely
across functions. also measure density, concentration and information. But, don’t lose sight of the
Another function that can benefit temperature, providing valuable data over ultimate goal: a fully connected com-
from data analysis is workforce man- and above just a flow reading that can pany that uses systematic, advanced
agement. Data from instruments can potentially be utilized to help refine pro- data analysis to improve efficiency, sat-
be used to create predictive mainte- cess performance. isfy customers and ultimately expand
nance routines based on actual per- Also, consider plant instrumentation its business. FC
formance, enabling employees to be that includes HART (highway addressable
deployed more effectively — with the remote transducer) capabilities, where
knowledge and tools needed to address a digital signal is superimposed onto an David Lincoln is a digital lead for ABB
any potential issues. analog signal. This is an ideal halfway Measurement & Analytics.

16 | November 2019 Flow Control

Features: Temperature Measurement

Moving beyond basic temperature

measurement instrumentation to
improve performance and reduce costs
Tools are available to get more from a temperature reading
than just a process variable, which can simplify installations
and deliver more reliable readings.
By Ryan Leino, Emerson

O
ne of the common challenges of Optimizing thermowell design using analysis
specifying industrial tempera-
ture measurement installations software minimizes flow obstructions and pressure
is sorting through the enormous range loss while extending equipment life.
of possible options and configurations
when selecting instrumentation and all in designing the process piping, it was • Secure ultimate termination at the
the components of the measurement loop anticipated that a temperature reading I/O card of the automation system.
— from sensor to the automation host would be useful, and a 3-inch flanged
system. In this article, two solutions to process connection was installed on the On the surface, it is a simple project and
the same straightforward installation are pipe, which has been closed with a blank should be easy to implement. The follow-
presented. The first illustrates traditional flange. The scope of the installation proj- ing examples illustrate the differences and
best practices with basic components. ect calls for the following: advantages between two approaches.
The second uses more advanced com- • Replace the blank flange with a
ponents and design techniques that can suitable flanged thermowell to Standard traditional approach
deliver a safe installation with a higher immerse the temperature sensor In a traditional approach, a hypothetical
degree of accuracy, greater reliability and in the liquid stream while providing engineer would select a stock thermowell
lower life-cycle cost. a terminal block for the electrical with a compatible mating connection and
The installation for this discussion connections. made from a suitable material. The inser-
involves adding a process temperature • Install a temperature sensor in the tion length should reach the center of the
measurement point to an 8-inch straight, thermowell and secure the neces- main pipe, so in this case, the insertion
horizontal section of Schedule 40 piping. sary terminations. length should be half the inside diam-
The process fluid is water with an aver- • Run appropriate extension wiring from eter of the 8-inch pipe plus the additional
age flow of 750 gallons per minute at the thermowell terminal block to the length of the spud. Given the length, a
pressure of 75 pounds per square inch automation host system via existing straight-stem thermowell with an outside
and temperature of 150ºF. Originally, cable trays and marshalling cabinets. diameter of 1 inch would be about right

Figure 1. Wiring with type K TC extension wire is simple,

but there are better ways to connect a sensor to an
automation system. All images courtesy of Emerson

www.flowcontrolnetwork.com November 2019 | 17

 Design analysis using sof tware
based on formulas outlined in the
ASME PTC 19.3 TW-2016 standard
can determine the viability for a given
thermowell profile based on its physical
strength and vibration characteristics
at specific operating conditions. With
effective software, it is a simple mat-
ter to work through what-if scenarios
to ensure the thermowell selected
will avoid VIV problems at a range of
operating conditions including startup,
product grade change, likely upsets
and others, in addition to “normal”
operation. Some plants have experi-
enced thermowell failures when run-
ning under abnormal conditions even
though analysis concluded the design
Figure 2. When a thermowell is inserted into a flowing liquid stream, vibrations caused by
wake-shedding effects can result in metal fatigue. was suited for normal conditions.
Undertaking this analysis using ther-
for this insertion based on other similar be desired. So, what is wrong, or less mowell design software and then invest-
installations in the plant. than optimal, about this approach? The ing in a more optimized thermowell with
For selection of a sensor, there are following considers an alternative. dimensions suited to the specific process
several possibilities suitable for the tem-
perature range. In this example, the engi- Analysis using thermowell
neer would select a type K thermocouple design software
(TC), since it is capable of handling any- A more advanced approach to this project
thing the process is likely to experience. includes selecting individual mea-
It can be connected to a home-run cable surement components to optimize
via the terminal block at the thermowell performance and safety while
head (see Figure 1). During a process reducing installation and future
shutdown, plant personnel remove the maintenance time.
blank flange and bolt the thermowell and Thermowell selection requires
sensor in place with a gasket. A reel of careful analysis to avoid main-
type K extension wire is sufficient to cover tenance problems related
the 200 feet from the thermowell to the to vortex-induced vibration
I/O rack of the host system via one mar- (VIV) caused by wake shed-
shalling cabinet. ding effects (see Figure 2)
While making the connections, the when a thermowell is inserted
technicians maintain correct polarity while into a flowing liquid stream per-
trying to place the cable in the trays as far pendicular to the flow direction. In
as possible from any existing power lines situations where the VIV frequency
to avoid electrical interference. Given the matches the resonant frequency of the
low voltage of the TC signal, all the termi- thermowell, the vibration can cause metal
nations must be checked carefully. fatigue, resulting in a break and loss of
At the I/O rack, the sensor extension containment.
cable ends at a temperature sensor card, To avoid this situation, many engineers
which can be configured for a type K TC will simply select an oversized straight-
so that the host system can display the stem thermowell profile, such as in the
Figure 3. Temperature transmitters come in
temperature measurement for the opera- previous example. This increases the many sizes and shapes and prevent signal
tors and it can be used in the larger con- internal pipe obstruction, slows response degradation. Installing one, such as Emerson’s
trol strategy. and may keep the sensor from reaching Rosemount 248 Temperature Transmitter in
a “puck” configuration, can be mounted in an
The solution selected for this project the full process temperature due to stem enclosure mounted on the thermowell,
is commonly used, but leaves much to conduction errors. as close to the sensor as possible.

18 | November 2019 Flow Control

will improve temperature measurement
Two independent sensors, even if they are wired to one
performance and liquid flow for the life
of the installation. transmitter, can reduce the probability of losing the reading
Selection of the specific sensor can by up to 80%, depending on the sensors‘ failure rate.
be debated. Some engineers might
prefer a resistance temperature detec-
tor (RTD) instead of a TC, but in a cabling, which can be expensive and only a more robust 4-20 mA current signal.
basic application such as this, either works with the specific sensor type. If This signal amplification makes it much
could work well. When evaluating the the plant decides to change from a Type less susceptible to interference present
differences, RTDs are generally con- K TC to an RTD or even a different TC in many plant environments. A current
sidered more accurate and stable type, the cabling will need to be replaced. signal can be carried by standard instru-
than TCs but tend to be more physi- Moreover, the automation system must ment cabling and added to the automa-
cally delicate and more susceptible have a dedicated temperature sensor tion host system via a standard 4-20 mA
to vibration. TCs typically respond to input, which may not work when switching input card. Similarly, wireless or digital
changes more quickly and are more from an RTD to a TC or vice versa, or even fieldbus protocols can be used if they
rugged than RTDs but can drift if their from one type of RTD or TC to another. are already deployed within the facility.
metallurgy changes due to prolonged If a different type of sensor is required,
exposure to high temperatures. Improving the it is a simple matter to reconfigure the
Many detailed resources are available measurement chain transmitter. Sophisticated HART and
on the RTD versus TC question, but a Adding a temperature transmitter (see fieldbus transmitters support remote
clear area for improvement is the use of Figure 3) at the thermowell terminal configuration and diagnostic functions,
direct wiring and the issues it presents. enclosure converts the weak voltage of which can call attention to developing
Either type of sensor requires dedicated a TC or small resistance of an RTD to problems and assist in troubleshooting.

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 Figure 4. Transmitters
such as Emerson’s
Rosemount 644
Temperature Transmitter
can read signals from
two redundant sensors
and detect problems by
comparing readings.

While transmitters have been in use for operating, so the transmitter can switch costs through the following advantages:
many years, developments in advanced seamlessly from a primary sensor to a • Better temperature measurement
diagnostics have been more recent. New backup sensor, reducing the chance of performance can help support pro-
features can identify changes to sensors losing a temperature reading. cess optimization.
indicating degradation before outright fail- The hot backup capability can be • Condition diagnostics reduce trou-
ure. While something basic like an open employed with a single dual-element sen- bleshooting and maintenance costs.
circuit or erratic transmission is easy to sor or two independent sensors. Risk of • Sensor selection options provided
identify, advanced transmitters (see Figure losing a measurement is reduced with two by the transmitter eliminates the
4) can use their capabilities to detect more independent sensors versus a single dual- need to replace cabling if changing
subtle problems that can lead to serious element sensor; however, this requires sensor type.
issues such as on-scale errors. additional process intrusions. Two inde- • Optimizing thermowell design using
For example, a transmitter designed pendent sensors — even if they are analysis software minimizes flow
to work with both TCs and RTDs must wired to one transmitter — can reduce obstructions and pressure loss while
have built-in capabilities to read both the probability of losing the reading by up extending equipment life.
voltage and resistance. If a TC is in use, to 80%, depending on the failure rate of • Eliminating higher-cost sensor wiring
it processes the signal by measuring volt- the sensors. Two sensors measuring the reduces installation cost.
age, but it still has a resistance circuit, same temperature can also be monitored
so it can be programmed to take resis- for drift by comparing their values via a While configuring advanced systems may
tance measurements of the TC element drift alert diagnostic. If the differential require some additional effort and engi-
at specific intervals. This can be done between the two readings exceeds a neering time, the results — improved
quickly to minimize any interference with user-specified baseline, it can indicate performance and reduced maintenance
a critical temperature measurement. This one of the sensors is degraded and has — are worth it. FC
resistance check provides a snapshot begun to fail.
of the condition of the TC and can be
used to detect deterioration capable of Advantages of Ryan Leino is a global tem-
causing problems with the temperature advanced solutions perature product manager
measurement. The initial instrumentation cost of the for Emerson’s Automation
When a temperature measurement is advanced solution can be higher than a Solutions business in Shakopee,
especially critical to a process, redun- more traditional approach; however, the Minnesota. He holds a Bachelor of
dant sensors can be an option. This adds advanced solution delivers critical opera- Science in chemical engineering from
an online “hot” backup capability while tional cost savings and lower installation University of Wisconsin, Madison.

20 | November 2019 Flow Control

Features: Valves

Laminar flow valves realized:

The flat-plate technology
This flat-plate valve technology and its operational characteristics
including laminar flow and faster fluid speed have the potential to change
the fluid control landscape, improve efficiencies and enhance processes.

By R. Barth Strempek and Thomas Christensen

I
n 1911, Dutch physicist Heike and molecules also be coaxed to flow characteristics while achieving full control.
Kamerlingh Onnes discovered the without impedance? But turbulence always seems to occur.
phenomenon of superconductivity. Therefore, the development of practicable
When certain materials are supercooled Laminar flow nonturbulent fluid control devices has
to critically low temperatures, resistance It has been shown that, under certain been elusive — until recently.
drops to zero. In 1937, Pyotr Kapitsa and conditions, turbulence in fluids can If there were a way to induce fluids to
John F. Allen discovered the phenomenon be minimized, leading to laminar flow. act as if there were no resistance — as if
of superfluidity. In supercooled helium, Thankfully, laminar flow does not require nothing were in the way, as if turbulence
viscosity drops to zero. Superconductivity supercooling. However, it has proven dif- did not exist — immense practical benefits
operates at the subatomic scale while ficult to realize the benefits of laminar might be achieved. If pressures and flows
superfluidity appears to manifest itself flow in fluid control valves due to the could be influenced in an instant without
primarily at the atomic scale but with necessary design restrictions (such as pressure spikes and interactive systems
quantum implications. A reasonable obstructions, barriers and edges) required effects, if fluid control devices could be
question to ask might be: If electrons can for operation. Consequently, laminar flow substantially reduced in size, if noise and
be induced to flow without resistance is primarily observed in pipes and linear vibration could be reduced, and if device
and helium atoms can be induced to stretches of flow, not in valves. The practi- activation could be achieved with minimal
flow without viscosity, can larger atoms cal problem has been to sustain laminar force, benefits would be significant.

Figure 1. Two
parallel flat plates
can induce laminar
flow in valves.

All images
courtesy of R. Barth
Strempek and
1a) Stacked plates (shut) 1b) Stacked plates (open) 1c) Stacked plates (surfaces) Thomas Christensen

www.flowcontrolnetwork.com November 2019 | 21

 After entering the device through the
input orifice, fluid rises around the outside
of the cylindrical bottom plate. When it
reaches the top edge of the plate, the
resistance of the cylinder itself disappears,
and the fluid shoots across the plate from
the entire circumference. The flow collides
in the center from all directions. An outlet
orifice (hole) is cut in the center of the bot-
tom plate directly below the fluid collision.
Fluid exits the device down this orifice. The
end result is fluid flow through the device
with no turbulence along the plate surfaces,
resulting in superior operation and control.
When the plates are pushed together,
the flow stops. When the plates are pulled
Figure 2. How the flat-plate valve technology works apart, laminar flow occurs across the
plate surfaces. Any turbulence occurring
Thirty years ago, a laminar flow valve be reconditioned or replaced. In high per- before reaching the edge of the plates or
design was developed to enhance the formance applications, this may require after the central collision is inconsequen-
efficiency of car wash operations. the expensive interruption of important tial to the operation of the device. It may
However, it went almost entirely unno- processes (e.g., hydraulic applications, be difficult to believe that this circuitous
ticed as knowledge and dissemination chemical processes or oil and gas extrac- route through the valve results in laminar
of the technology was stifled, initially by tion/processing). Turbulence also causes flow — but it does.
lack of vision and later by a combination noise and vibration that increase over As illustrated in Figure 2, the basic
of technology-driven strategy, misman- time as valve integrity deteriorates. topology of flat-plate devices is radically
agement and other failings. Precision applications requiring quiet different from other fluid control (valve)
The good news is that a laminar flow operation and accuracy are greatly dis- designs. It must be noted that these
valve technology exists that can solve a rupted by excessive noise and vibration. devices are not devoid of turbulence;
wide variety of fluid control problems, yet Consequently, these inefficiencies drive instead, they manage turbulence so that
industry structure and lack of resources valve designs to be larger and less effec- it occurs in only noncritical areas at input
continue to constrain widespread imple- tive than they should be if turbulence and output. At input, fluid slows so that
mentation. The following outlines the did not enter the equation. Turbulence it can be fed evenly to the operational
critical elements and properties of this can nearly be eliminated from the valve surfaces (parallel plates). After passing
groundbreaking technology. equation by using two cylindrical, parallel between the two plates and colliding in
flat plates. the center, the resulting fluid collision is
Turbulence: The bane of
fluid control
Turbulence in a valve causes a variety of
These devices are not devoid of turbulence;
negative effects such as cavitation, K fac- instead, they manage turbulence so that it occurs
tor head loss, noise, vibration, imprecise
in only noncritical areas at input and output.
control and excessive wear. Cavitation is
particularly troublesome in some fluids
such as water. Water contains dissolved How flat-plate devices work constrained by the top plate and forced to
gases, which, when accelerated through Most valve designs are some version of a occur within the output orifice where the
a constriction, form small bubbles that plug in a hole or a barrier across an open- effects of turbulence are noncritical for
implode with enough force to cause min- ing that inevitably introduce turbulence. control purposes and are damped within
ute bits of metal to be dislodged from The resulting negative consequences are the output orifice and by the fluid-to-fluid
the edge of valve seats and housings. extremely difficult to ameliorate. The flat-plate collision itself before exiting the device.
In time, enough metal erodes from the technology uses a unique internal topology
valve surfaces that the device begins to to generate laminar flow within the device, Properties of
leak, and control properties (ability to pre- thus nearly eliminating most of the unwanted flat-plate devices
cisely regulate flow and/or pressure) are effects. The basic design consists of two par- Flat-plate valve prototypes with through-
diminished. Eventually, the valves must allel flat plates (as shown in Figure 2). puts ranging from a few ounces per minute

22 | November 2019 Flow Control

 The fluid accelerates
from a modest speed
when it begins its journey
across the plates to its
maximum at the point
of the center collision.

were reengineered to be only marginally

better than existing valves to accommo-
date a poor business model by manage-
ment. The company subsequently resisted
further technological innovation.
In the ensuing years, the inventor made
two more attempts to develop and market
advanced versions of the technology. He
raised several million dollars for his sec-
Figure 3. Regulator/relief valve rated at 200 gpm at 5,000 psi
ond commercial attempt. Various advanced
designs were tested on hydraulic, oil and
to 1,200 gallons per minute (gpm) have This technology has the potential to gas, chemical and water applications. For
been built and tested. The most interesting rewrite the book on fluid control. It is also two years, prototype choke valves handling
operational prototypes (control and relief important to consider the applications seawater and crude oil were successfully
valves) are rated at up to 200 gpm at that may take advantage of the curious operated on oil platforms off the West Coast
between 5,000 and 6,000 pounds per phenomenon occurring in the center of with no apparent wear. Unfortunately, various
square inch (psi). They are surprisingly these devices — the fluid-to-fluid collision management and strategy issues prevented
compact at 14 to 18 inches tall and weigh at immense speeds. This phenomenon this company from becoming operational.
between 50 and 80 pounds (lbs). occurs in devices that were designed for The most sophisticated prototype utilizing
Interestingly, what happens in the fluid control, not maximum fluid speed. the original technology and its improve-
center of these devices is not well under- Some observers familiar with this technol- ments is a regulator relief valve rated at
stood. The operational surfaces of the ogy have speculated that devices might 200 gpm at 5,000 psi (see Figure 3).
flat plates are only a few inches in diam- be designed to amplify that speed sev- The inventor’s third company developed
eter. When operating fully open, the aver- eralfold, making possible applications an even more sophisticated version of
age speed of fluid across those surfaces to sterilize water mechanically, create
is several hundred miles per hour. The new chemicals, alter molecular bonds
fluid accelerates from a modest speed or improve water saws, for example.
when it begins its journey across the These possibilities are speculative and
plates to its maximum at the point of the untested. Yet, there is something previ-
center collision — perhaps well over a ously unknown and poorly understood
thousand miles per hour. No erosion has happening in the interior of these valves.
ever been observed on the surfaces of
the plates. Clearly, laminar flow is occur- Where has this
ring here, producing some jaw-dropping technology been?
measurements. The original inventor developed the earliest
Another critical design element is the version of this technology to control water
narrow separation between the plates. and chemicals for car washes. The tech-
To open or close these devices, the top nology allowed 12 bays to be handled
plate needs to move only a fraction of an on one water line, whereas the previous
inch. Therefore, actuation from fully open systems could only handle four bays. The
to fully closed (or vice versa) is extremely inventor formed his first company to manu-
Figure 4. Full-balance control valve rated at
fast, resulting in near instantaneous acti- facture and market these valves. However, 200 gpm at 6,000 psi. It can be actuated with
vation with minuscule pressure spikes. over the objection of the inventor, the valves minimal force.

www.flowcontrolnetwork.com November 2019 | 23

the technology that is balanced for both speed could have significant applications planning. Dr. Strempek taught at Radford
upstream and downstream conditions. in new directions beyond fluid control. FC University, Virginia Tech, and Elon University
The existing prototype is a control valve where he was named the first Doherty
rated at 200 gpm at 6,000 psi (see Figure Authors’ note: Thomas Christensen, co- Professor of Entrepreneurial Leadership
4). This advanced technology allows inventor of the full-balance technology, and was awarded emeritus status upon
devices to be actuated with very small has been part of a group led by Barth his retirement in 2017. He can be reached
forces (a few ounces) against very large Strempek who, following the passing of at strempek@elon.edu or 919-356-1226.
pressures (greater than 6,000 psi). The the original inventor, spent several years
device is only 17 inches tall, 5.5 inches reassembling the pieces of this technol- Thomas Christensen holds undergraduate
in diameter, and weighs approximately ogy (prototypes, patents, designs, files, and graduate degrees in agricultural engi-
80 lbs. By the time this device was per- etc.). These pieces had been dispersed neering from the University of Maine. In
fected, the inventor was in his 80s and among various entities. his early career, he worked as a research
was unable to attract serious capital for engineer for Caterpillar Tractor Co. Upon
another attempt at commercialization. returning to the University of Maine, he
R. Barth Strempek, Ph.D., holds an under- spent 40 years teaching engineering
Conclusion graduate civil engineering degree from MIT, and conducting fluid power and machine
This sophisticated technology has the a Master of Business Administration (MBA) development research until his retirement
potential to alter the landscape in fluid from Harvard, and a doctorate in strategic in 2013, when he was awarded emeritus
control, which would be a considerable management from Virginia Tech. His career status. Christensen also worked as the
contribution to industry if it is widely avail- began as a transportation engineer at company engineer for an industrial fluid
able. It also has the ability to improve effi- Parsons, Brinckerhoff, Quade and Douglas power supply company for 14 years and
ciencies and enhance industrial processes. in NYC and later at Conrail, R. L. Banks, & was a licensed PE for over 38 years. He
Additionally, the technology’s properties of Assoc., Informatics General Corporation, can be reached at 207-299-4334 or
laminar flow combined with blazing fluid and CSX Corporation as director of corporate springwoodindustries@yahoo.com.

24 | November 2019 Flow Control

Features: Sealing

Predicting sealing quality by

filtering surface texture data
Modern texture analysis software can predict sealing performance
and address root causes of potential leakage.
By Mark Malburg, Digital Metrology Solutions

T
he shape and texture of a surface Most surface functionalities are not measurable purely in
is critically important to its func-
tionality. This is particularly true in
units of height. Local curvatures and the connectedness
sealing applications. Today, there is no of surface features can provide more valuable insight.
shortage of instruments for measuring sur-
face texture. Yet, despite the great amount in contact. Furthermore, they are well- valley height (Rz). In some cases, a wavi-
of data that can be gleaned from surface suited to predicting how a relatively soft ness height (Wt) may also be specified.
texture measurements, most engineers surface (e.g., a gasket or seal) will interact These parameters are well-known and
continue to specify only basic height-based with a relatively rigid surface. This article readily measurable with most surface
parameters, such as average roughness discusses how sealing performance can profiling instruments.
or total flatness. (See Figure 1.) be predicted with this analysis via modern Unfortunately, these statistics do not
The challenge, however, is that most surface texture analysis software. necessarily indicate how the surface will
surface functionalities (sealing, for exam- perform. Figure 2 shows two very differ-
ple) are not measurable purely in units of Can average roughness ent surfaces with virtually identical Ra, Rz
height. Local curvatures and the connect- distinguish a “good” and Wt values. If these parameters were
edness of surface features can provide sealing surface? specified on a print, the two surfaces
much more valuable insight. As previously mentioned, the most com- would be virtually indistinguishable and
In recent years, morphological filters monly specified surface finish parame- would pass similar quality control test-
have been introduced in surface texture ters in sealing applications are based on ing. Yet, none of these parameters would
literature and standards. The morphologi- heights measured along a profile. These reveal that the repeating milling pattern
cal opening and closing filters provide a common parameters include average in the second surface could create leak
powerful means of simulating surfaces roughness (Ra) and average peak-to- paths between mating surfaces.

Figure 1. By properly analyzing surface texture,

leak paths on a sealing interface can be predicted.
All images courtesy of Digital Metrology Solutions

www.flowcontrolnetwork.com November 2019 | 25

Both closing and opening filters can be adjusted
in real time, letting engineers explore how
changes in materials, processes and tolerances
might improve performance.

Figure 3. A closing filter acts as a virtual gasket

placed onto the test surface, pressing into the
peaks and leaving voids below. An opening
filter exposes peaks that are sharper than a
given radius, which may concentrate stress.

Figure 2. Parameters such as Ra, Rz and Wt moved along the surface data. For the be altered in real time. With a smaller
have identical values for both surfaces yet offer closing filter, the virtual ball rides along radius, the ball will enter more val-
little insight into how the parts will perform.
the surface. A closing filter acts as a vir- leys, thereby modeling a more compli-
tual gasket that follows the peaks and ant gasket material. Raising the cutoff
New surface texture leaves voids in the regions of the val- wavelength for the waviness profile will
filters provide insight leys. By analyzing the gaps created by the increase how much the virtual gasket
into function closing filter, potential leakage under an will “crush” peak material.
In recent years, new parameters have actual gasket can be predicted. This article focuses more attention on
been developed that closely correlate with For an opening filter, the ball is essen- the closing filter.
particular functionalities. Engineers can tially pushing up from below the surface. The path of the closing filter (as shown
use these functional parameters to com- The opening filter highlights the peaks in in black in Figure 3) may be an inter-
pare design options during development a surface that are sharper than a given esting presentation of the amount of
and then specify these parameters on radius. These sharp peaks can be related deformation to be expected by a seal or
prints to improve component performance to oil film penetration points or cosmetic gasket. However, the difference between
and longevity. defects, or stress concentrations that the measured surface and closing filter
One such functional analysis is based could lead to cracking. is much more important: It is a direct
on using surface texture filters that can One crucial aspect of this type of representation of the cross-sectional
simulate the shape of a mating surface. analysis is that both closing and open- leakage area.
Figure 3 shows morphological opening ing filters can be adjusted in real time, This surface texture analysis method
and closing filters applied to a surface. letting engineers explore how changes provides direct modeling of the sealing
The filter in these examples is the in materials, processes and tolerances interface. Thus, it is a valuable method
path of a virtual circle (or ball for 3D might improve performance. For exam- for understanding and controlling the root
measurements) of a given radius that is ple, the radius of the closing filter can causes of leakage.

26 | November 2019 Flow Control

 Figure 4. Standard surface
texture parameters could not
discern a difference between
these two surfaces. However,
the Wvoid parameter, generated
based on a closing filter, shows
more than nine times the leak
area in the second profile
relative to the first surface.

Case study: Using a closing

filter to predict leakage
In Figure 2, the two surfaces shown are
indistinguishable by common surface
texture parameters. In Figure 4, these
surfaces are revisited with a different
analysis approach. A closing filter, or vir-
tual gasket (shown in black), with a radius
of 5000 mm, has been applied to the
waviness profile (red) for both surfaces.
When the closing filter is applied to the
first surface, it closely follows the wavi-
ness profile. Although the waviness is
quite large in terms of total height, there
are no abrupt changes that would cause
significant leak areas.
However, when the same closing filter
is applied to the second surface, large, Figure 5. On the left, a closing filter (transparent blue) interacts with the measured surface.
periodic voids are shown that cannot be The difference between the closing surface and measured surface creates the void surface
(shown on the right). The void surface represents the void areas where leakage may occur.
sealed by the virtual gasket. These voids
are of concern.
While the profile graphs clearly show quality. The parameter is normalized per applied across the dataset (on left) to
the difference in sealing, a numerical unit length, making it independent of the create the closing surface, shown in
value to indicate the amount of leak- evaluation length and therefore more transparent blue. On the right, the gaps
age could be desirable to specify and repeatable and stable. between the closing surface and mea-
control these critical surfaces. The This analysis can be extended into sured surface are shown as a void sur-
functional parameter Wvoid (void area three dimensions as well. Figure 5 face, which represents the void areas
per unit length) was developed to sat- shows the application of a closing filter where leakage may occur. As with the
isfy that need. Wvoid, which is shown to a measured surface using interactive 2D analysis, changing the radius of the
via the OmniSurf software in Figure 4, filtering tools in OmniSurf3D software. closing filter can be related to changes in
can be tracked as a measure of sealing In Figure 5, the closing filter has been conformability and sealing forces.

www.flowcontrolnetwork.com November 2019 | 27

 Figure 6. Pit and
Porosity analysis
helps determine which
voids in a surface may
become leak paths.

In Figure 6, the green regions are edge-connected

regions, representing potential leak paths that are open
along either the X or Y axis of the data set.

Using Pit and Porosity At any cross-sectional height level, the specified on prints to guide production
analysis to trace leak paths open and closed pores can be counted. and track surface quality. FC
Other advanced analyses can help Or, the pit density, the number of pits per
determine which voids in a surface may square centimeter, can be calculated.
link up to form leak paths. In Figure 6, Pit density can give a better indication Dr. Mark Malburg is a sur-
an interactive Pit and Porosity analysis of the surface in general, irrespective face metrologist with BSME
(shown in OmniSurf3D software) has of the size of the measurement area. and MSME degrees from
been applied to a surface to analyze Analysis tools like this make it easy to Michigan Technological University and
the voids, or pores, which may lead visualize what is happening and provide a doctorate from the University of
to leakage. The analysis shows a 3D traceable numbers. Warwick. Dr. Malburg spent 10 years
map of surface heights on the left, in industry prior to forming Digital
the material ratio curve in the middle, Conclusion Metrology Solutions in 1999. Digital
and a plot of pores and leak paths on Surface texture filters and functional Metrology provides custom metrology
the right. parameters make it possible to quickly software development, training and con-
The porosity features shown in red are and easily measure the properties of a sulting, and it has developed numerous
considered closed pores, meaning that surface that are most specifically tied surface texture analysis software pack-
they are completely enclosed by mate- to a desired function. ages including OmniSurf, OmniSurf3D
rial at this given cutting plane. Blue A morphological closing filter can and OmniRound. Dr. Malburg’s work,
features are open pores, meaning they provide insight as to how well a sur- mathematics and software are incorpo-
open onto the edge of the data set. The face will seal and provide insight about rated into many commercial measuring
green regions may be the most impor- other functionalities. These filters can systems. Visit digitalmetrology.com or
tant. These are edge-connected regions, be used to explore changes to mate- email info@digitalmetrology.com for
representing potential leak paths that are rials and methods that may address more information.
open along either the X or Y axis of the the root causes of sealing issues, as
data set. well as provide parameters that can be

28 | November 2019 Flow Control

 P R O D U C T

FOCUS
Send products for consideration in this section
to mrogers@endeavorbusinessmedia.com

3
2

1 | rugged tablet 2 | blowdown valve 3 | metering pump 4 | ultrasonic clamp-on

Endress+Hauser’s Field CIRCOR’s RTK Bottom Flowrox’s FXM Metering
flowmeter
Xpert SMT77 is a tablet Blowdown Valve features a Pumps, FXM-2 and FXM-3 Badger Meter’s Dynasonics
PC tool for managing field unique angle design that offers for chemical applications, TFX-5000 ultrasonic clamp-on
instruments and documenting quick, problem-free clearing allow operators to monitor flow and energy meter is
work. It is preinstalled with of particulate and dissolved the pumps 24/7 with the designed for noninvasive,
device configuration software solids from the bottoms of use of a computer or mobile ultrasonic transit time
and device library, with over steam and hot water boilers. device. The Flowrox Malibu measurement. The meter
2,700 drivers, allowing it to The valve’s seat design portal can remotely manage, measures volumetric flow
work with different instruments features hardened trim and an measure and analyze and heating/cooling rates in
from a range of vendors. It anti-flashing seat that protects processes from anywhere clean liquids and those with
enables asset management the valve body from cavitation with an internet connection. small amounts of suspended
in Class 1, Div 1 hazardous and flashing effects. The angle The maximum flow of the solids or aeration. The
areas. It can connect to field design manages and reduces FXM-2 is up to 46.5 gph, unit can be selected with
instrumentation devices via pressure in a single-stage and the FXM-3 is up to particular configurations and
a USB or Bluetooth wireless configuration for PN 63/DN 20 221.9 gph. Working features. Users can select
modem, or via a gateway, to PN 160/DN 50 applications. pressure is up to 125 psi, up to eight parameters, and
remote I/O or multiplexer to Pneumatic-powered or manual withstanding ambient temps users are alerted to out-of-
a bus system. actuation is available. of up to 131ºF. specification flow conditions.

www.flowcontrolnetwork.com November 2019 | 29

 2

1 | actuator 2 | wireless level 3 | caliper tool 4 | solenoid and

GF Piping Systems’
transmitter Probe’s UHT Dimension XY
motor-driven pumps
Smart Actuator can be fully Emerson’s Rosemount Caliper is designed to operate Neptune’s NSP Series
monitored and, if required, 3308 GWR Wireless Level in ultra-high temperature Solenoid Metering Pump
controlled, via an app on a Transmitter complies with environments. It expands upon features a durable solenoid
smartphone or tablet. After the API 18.2 standard that the Kuster geothermal logging drive equipped with double-
initial startup, the app provides guidance for crude tool portfolio. Developed to ball valves. It has a compact
displays existing valves with oil custody transfer from operate in environments up design and is available
previously assigned names. small lease tanks. Accuracy to 325°C (617°F), the tool in manual-, analog- and
Operating instructions are not can be verified without having provides two continuous pulse-controlled models. The
required. The valve actuator to open a tank’s thief hatch. independent perpendicular Neptune NXP Series combines
offers flexible upgrade due An upgraded microwave measurements (X and Y) of advantages of a solenoid-
to an ISO-5211 interface; module has made it more the internal diameter of the driven pump with a motor-
better visual control with 360° tolerant to difficult process casing. The tool produces a driven pump to feed chemicals
LED display; wireless control; conditions and able to deliver high-resolution temperature in accurate applications. It is
flexible planning; convenient a more sensitive, repeatable profile of the well via an adjustable, and the stepper
preconfiguration and quick measurement. With no external fast-response motor with wear-free tooth belt
commissioning; and better moving parts, calibration is resistance temperature dive ensures a homogeneous,
data handling and control. not required. detector (RTD). gentle dosing process.

30 | November 2019 Flow Control

 Connect
SOLUTIONS FOR FLUID MOVEMENT, MEASUREMENT & CONTAINMENT

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Flowrox......................................................................................... 15 Spitzer and Boyes LLC................................................................... 24

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www.flowcontrolnetwork.com November 2019 | 31

 FEATURED
CONTENT

FlowControlNetwork.com

Courtesy of United Electric Controls

@FLOWCONTROL_MAG

Congratulations to the 2019

#InnovationAwards winner
Ham-Let, and honorable
mentions: Endress+Hauser,
Fluid Components
International, Emerson
Automation Solutions, and As the use of natural gas continues to grow, the need to minimize
VorTek Instruments. Read leaks in storing and transporting will grow with it. Separating
about their innovative the tasks of detecting leaks and locating leaks makes it easier to
solutions: ow.ly/n84C50wgNtO automate the detection process, so the more time-consuming process
of locating the leak can be used only when triggered.
An alternative control panel –Andrew Liptak, United Electric Controls
option, the board level
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discrete #PID controller at WHAT'S ON FACEBOOK
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machine model-based
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32 | November 2019
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