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.

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

Thursday, February 28, 2019

The Yokogawa YS1700 Replaces Obsolete Siemens/Moore 353

Yokogawa YS1700
Now that entire Moore/Siemens 350 family is obsolete, are you considering upgrading to a DCS?
Are you concerned about the cost and time for a new installation, application development and personnel training?

Is it possible that the new equipment vendor may again leave you stranded with their equipment as their core business is not industrial automation and control?

We have a better solution for you: Yokogawa and its YS1700 PID loop controller. Yokogawa has been providing industrial solutions, as their primary business, for over a century and their YS1700 will keep you off of eBay looking for spare 353 parts.

Monday, February 25, 2019

Pneumatic Actuator Types

Pneumatic valve actuators all provide the same function:  They convert air pressure to rotational movement and are designed to open, close, or position a quarter-turn valve.  These include ball valves, plug valves, butterfly valves, or other types of 90 degree rotational valves.

The basic design variations of pneumatic valve actuators are as follows:

  • Scotch-yoke
  • Rack and pinion
  • Rotary vane

Let's review each of these in detail:

Scotch-yoke Actuators

Scotch-yoke ActuatorThese actuators come in a multitude of sizes, but are usually used on larger valves because they can produce a very high torque output.  They employ a pneumatic piston mechanism to transfer movement to a linear push rod.  That rod, in turn, engages a pivoting lever arm to provide rotation. Spring return units have a large return spring module mounted on the opposite end of the piston mechanism working directly against the pressurized cylinder.

Rack & Pinion Actuators

Rack & Pinion Actuator
These actuators are sometimes referred to as, “lunch box,” because they, well, look like a lunch box. This actuator uses opposing pistons with integral gears to engage a pinion gear shaft to produce rotation. They are usually more compressed than a scotch yoke, have standardized mounting patterns, and produce output torques suitable for small-to-medium sized valves.  Rack and pinion nearly always include standard bolting and coupling patterns to directly attach a valve, solenoid, limit switch or positioner.  One of their features include several smaller coil springs mounted internally, which provide the torque to return the valve to its starting position.

Rotary Vane Actuators

Rotary Vane Actuator
These actuators are usually used when the application requires a significant space savings.  They take up less space when comparing size-to-torque with rack and pinion and scotch yoke. Rotary van actuators also benefit from a reputation of longevity.  They contain fewer moving parts than other types of pneumatic valve actuators.  Rotary vane actuators use externally mounted, helically wound "clock springs" for their spring return mechanism.

When considering the choice of pneumatic valve actuators, your decision comes down to size, power, torque curve and the ease of adding peripherals. To ensure that your valve actuation package will be optimized for safety, longevity, and performance, the advice of a qualified valve automation expert should be sought out. That expert will be able to help you with the best selection of the appropriate valve actuator for any quarter turn valve application.

Friday, February 15, 2019

The VEGA MINITRAC 31 Radiation-based Density, Level, and Flow Measurement Sensor

Radiation is a popular means of density measurement in several industries, including refining and offshore oil and gas.  The VEGA MINITRAC 31 is suitable for liquid and bulk solids applications in vessels that present mechanically difficult process conditions. The measured value is detected non-intrusively, right through the vessel wall. Process fittings and vessel openings are not required. The instrument is therefore ideal for retro-fit applications. The VEGA MINITRAC 31 can be used for many different measuring tasks. Apart from density measurement and level detection, the MINITRAC 31 can also detect residues and the mass flow rate when used in conjunction with a flow meter. This video demonstrates how the sensor uses radiation to reliably and accurately measure the density of liquids and slurries and how operators can use Bluetooth-enhanced display modules for wireless remote access to density sensors.

Classic Controls, Inc.

Thursday, January 31, 2019

Industrial Flow Meter Selection

Industrial Flow Meter Selection
Flow meter selection chart. Click on image for larger view.

Many industrial process control operations require fluid flow measurement as an essential element in the design of the process. The proper application and installation of a flow meter as part of the fluid transfer system will provide accurate flow measurement.

Industrial flow meters use different technologies to measure fluid flow rates directly or indirectly. Some of the most common technologies for fluid flow measurement are vortex flow meters, magnetic flow meters, Coriolis flow meters and rotameters.

Each separate technology has attributes that can make it more suitable for certain applications. The selection of the most appropriate flow measurement technology for an application is an initial and crucial step in the design of a functioning fluid measurement system.

Selection criteria such as fluid temperature, pressure and velocity will be included in the selection process. Further considerations include whether the fluid may be abrasive, corrosive, clean or dirty. The state of the fluid, liquid or gas, must also be taken into account.

The table above provides general guidance on which technologies to consider, based on the above mentioned factors. This will help you to focus further research on product selection.

Contact Classic Controls with any industrial flow application you may have. Their application engineers will provide guidance and advice to assure the proper flow meter is chosen.

Classic Controls

Monday, January 28, 2019

Magnetic Level Indicators (MLIs) and Bridle Combination Units

Magnetic level indicators
Magnetic level indicators provide highly visible indication of level with or without signal outputs monitoring tail and vessel level. The term bridle is used to describe a vertical pipe connected to the side of a storage tank or process vessel, most often with side-to-side or side-to-bottom connections. Because the fluid inside the bridle rises and falls equally with the level of fluid inside the tank or vessel, bridles have been adapted for level measurement use on a broad scale.
Magnetic level indicators

Below is a good instructional reference document (courtesy of VEGA) on how magnetic level indicators (MLIs) are installed and how they work.

Download the "Magnetic Level Indicators and Bridles for Level Measurement and Visualization" document here.

Wednesday, January 16, 2019

Yokogawa SENCOM™ for SMART Liquid Analyzer Communications

SENCOM™ technology allows sensors to transmit and receive data when connected to a FLXA202 or FLXA21 transmitter or to any PC with the SPS24 software installed. Yokogawa SENCOM™ SMART is digital communication designed to optimize your process. Digital or SMART sensors maintain specific measurement and calibration data on an integrated chip and an integral part of the sensor. This data can be exchanged between the sensor and either a process transmitter or a laboratory PC using a data management software, like the SPS24.

For more information, contact Classic Controls by calling 863-644-3642 of visit