Wednesday, June 19, 2019

Basics of Rotameters

Rotameter operationRotameters, also referred to as variable area flow meters, have diverse industrial processing applications that range from simple to sophisticated. The devices are easy to install, require no electrical connection, and provide direct flow rate reading. They provide fail-safe flow rate readings in a wide array of industrial applications.

Rotameters: An Overview 

Developed by German inventor Karl Kueppers in 1908, Rotameters measure the volumetric flow rate of liquids and gases.

Important elements of a rotameter (variable area flow meter) include the tube and the float. Their operation is simple. The tube is fixed vertically and the fluid is fed from the bottom. It travels upward and exits from the top. The float remains at the bottom when no liquid is present and rises upward when fluid enters the tube.

The float inside the tube moves in proportion to the rate of fluid flow and the area between the tube wall and the float. When the float moves upward, the area increases while the differential pressure decreases. A stable position is reached when the upward force exerted by the fluid is equal to the weight of the float. A scale mounted on the tube records the flow rate of the liquid. Usually, the flow can be adjusted manually using a built-in valve.

Types of Rotameter 

Variable area flow meters can be categorized by the type of tube they use, which relates to their ability to withstands various pressures, temperatures, process media, and cost. Process connection size and wetted part materials vary as a function the rotameter type and construction.

Glass Tube Rotameter
Glass Tube Rotameter
(Yokogawa)
Glass Tube Rotameter - The basic glass variable area flow meter consists of borosilicate glass tube while the float is made of either glass, plastic, or stainless steel. The most common combination is a glass tube and metal float. This is suitable for a measure the flow rate of liquid of low to medium temperatures and pressures.

Applications:

  • Analytical instrumentation
  • Industrial processes
  • Chemical production
  • Pharmaceutical production
  • Oil & gas extraction
  • Refining processes
  • Fuel cell research
  • Water treatment systems

Metal Tube Rotameter
Metal Tube Rotameter
(Yokogawa)
Metal Tube Rotameter - Metal tube variable area flow meters are another type that is suitable for temperatures and pressures beyond the physical and mechanical limits of glass tube versions. They are generally manufactured of stainless steel, aluminum, or brass. The piston position is determined by the mechanical and magnetic followers that can be read from the outside of the tube. They are suitable in situations where applications conditions would damage the glass metering tubes, such as steam applications.

Applications:

  • Purge liquid/ gas metering
  • Liquid, oil, or gas flow measurement
  • Chemical injection
  • Rotating equipment flow measurement
  • High-pressure flow meters on offshore oil platforms
For more information, contact Classic Controls.
https://classiccontrols.com
863.644.3642

Friday, May 31, 2019

Clamp-On Ultrasonic Flow Meters: Measure from the Outside of the Pipe


Conventional measuring systems such as differential pressure meters, electromagnetic flowmeters, vortex meters or Coriolis mass flowmeters require costly pipe modifications and experience increased wear resulting in frequent maintenance intervals. FLEXIM is the technology and market leader in the field of clamp-on ultrasonic flowmeters that eliminate the need for pipe entry points, eliminate wear,  and does not require shutdown for maintenance.

For more information, contact Classic Controls.
https://classiccontrols.com
863.644.3642

Friday, May 24, 2019

Globe Control Valves

Globe Control Valves
Internal view of globe control valve (Masoneilan)
Globe control valves work differently when compared to gate valves, ball valves, butterfly valves and plug valves in process control applications. They are primarily used to control the flow inside pipes, and are popular in a wide variety of industries. Globe control valves are ideal in situations where precise control is required. They are used to regulate flow in pipelines with a high degree of accuracy by regulating a pressures drop created in the valve body that allows the fluid to pass through the passageway (port) in the valve body. The control valve stem provides linear motion to bi-directionally control flow, opening and closing the valve by changing the distance between valve disc and seat. The flow in the pipeline changes according to the position of the disc lifting from the seat. The movement is controlled through the use of manual operators, or through the use of electric or pneumatic actuators.

Applications of Globe Control Valves 

Globe control valves are used in many different industries, but particularly in the petrochemical and power generation industries on fuel oil pipes, chemical feed systems, steam pipes, as well as cooling water and feedwater systems.  Other industrial applications of globe valve include boiler, main steam vents, and turbine lube oil systems.

Pros

Globe control valves have many advantages that make them preferable over other valve designs. Globe control valves have excellent shut-off and throttling capabilities. In addition, globe valves are easy to maintain and repair compared to other valves.

Cons

Globe control valves have also certain shortcomings. For instance, globe valves have an S-shaped flow pattern (as opposed to a straight-through flow pattern) which creates a significant pressure drop making them unsuitable for applications constant pressure is required.  Another shortcoming of the globe valves is they generally require greater torque to open and close, requiring larger actuators to properly seat the valve.

For more information on industrial globe valves, or any type of industrial valve, contact Classic Controls by calling 863-644-3642 or by visiting https://classiccontrols.com.

Friday, April 19, 2019

Reduce Standby Cycling to Optimize Boiler Operation

gas fired boilers in a boiler room
There are savings to be had by controlling boiler standby cycling
Heating of commercial and institutional buildings presents a case where there are energy savings available through the application of an additional controller able to substantially reduce boiler operation time.

Building owners, boiler engineers, operators and other stakeholders will benefit from this simple and understandable video explanation of some of the inefficiencies associated with boiler operation, and how incorporating a better control method can minimize boiler dry firing (also called standby cycling). Boiler operation costs can be reduced between 10% and 25%, with a commensurate reduction in carbon footprint, by including the Fireye NXM2G control in the boiler control system.

Watch the video. It's just a few minutes and explains the source of the inefficiency, as well as the solution, in a manner understandable to everyone. More information is available from a combustion product specialist, who can help evaluate the efficiency of your current system or assist with incorporating the latest energy saving features and design into a new installation.

Monday, March 25, 2019

Clamp-on Ultrasonic Flow Measurement of Natural and Process Gases


FLEXIM‘s ultrasonic gas flow meters use the proven clamp-on transit-time correlation technique also employed for the F series liquid meters. Special ultrasonic transducers are simply clamped onto the outside of the pipe and never come in contact with the gas.

FLUXUS® G represents the ideal solution for non-invasive gas flow measurement. FLEXIM’s non-invasive technology is an advantageous and cost-effective alternative to conventional methods, particularly with chemically aggressive, poisonous or high pressure media. With their extremely wide turn-down ratios, the instruments of the FLUXUS® G series register even the smallest flows.

Non-invasive Measurement

  • No contact with the medium, therefore no possibility of chemical attack. No need for expensive special materials (sour gas applications for example)
  • No wear and tear, even with high flow velocities or with gas containing particles
  • No clogging of small bore impulse lines with deposits, condensate, inhibitors, oil vapors, dust (as happens when using impulse lines in the measuring system)
  • Insensitive to dust and humidity

Classic Controls, Inc.
https://classiccontrols.com
863-644-3642

Tuesday, March 12, 2019

Plant-wide Condition Monitoring

In addition to the most important assets found in industrial facilities, there are often a host of “supporting” assets that make up the balance of the plant such as pumps, motors, blowers, heat exchangers, fans, and others. This auxiliary or plant-wide equipment may be spared or sacrificed, and its impact on the process stream may vary from moderate to minor. Regardless, such machines—just like their more highly important counterparts—can benefit from Condition Monitoring. Condition Monitoring provides affordable, effective portable and permanent condition monitoring solutions that are delivering tangible benefits for tens of thousands of customers around the globe.

Financial Justification

For many assets, failure can mean substantial or total loss of production, often worth millions per day. Or it can lead to the release of hazardous substances, fires, and even explosions— resulting in a severe safety hazard as well as fines for violating environmental regulations.

Maintenance Costs

When viewed on a per-asset basis, maintenance costs for plant-wide assets can appear modest. However, when viewed collectively across the dozens, hundreds, or even thousands of assets in a typical plant, these costs can be appreciable. Reducing the maintenance costs on each asset through effective condition monitoring—even by a mere 10%—has a large impact on plant profitability. Condition Monitoring is a planning tool that allows more effective insight in planning and asset management, allowing maintenance to be done in advance of a functional failure.

Things to think about as you move towards Predictive Maintenance:
  • 90% of failures are NOT time-based.
  • 50% of companies site maintenance and reliability as a top priority.
  • It costs 6x as much for unplanned events vs. planned maintenance in process industries.
  • A 60% estimated increase in environmental, health and safety spending among global exploration & production companies.
  • 50% of workforce to retire in the next 5 to 10 years. Knowledge & experience is not being transferred.
Potential impact of a conditioning monitoring program and the move towards Predictive Maintenance:
  • -70% Machinery breakdowns 
  • -40% Plant downtime
  • -50% Maintenance costs
  • +25% Production
For more information on Plant-wide Condition Monitoring, contact Classic Controls by calling 863-644-3642 or visit their web site at https://classiccontrols.com.