Flow Control June 2019

Trade Show Preview
EASA 2019
Page 30
Motors
& Drives
Energy-saving technologies
for pump systems
Also Inside
Nominations for
Innovation Awards
Roller bearing failure

and prevention strategies
Asset-specific apps
for plant operations
JUNE 2019 • Vol. XXIV, No. 6

www.flowcontrolnetwork.com
AHR EXPO
PREVIEW
Page 28
FLUID
Density
The effects of
temperature and
pressure
Also Inside
Automating custody transfer

level measurements
Ultrasonic flowmeters for

HVAC monitoring
Performing a storage
tank risk assessment
JANUARY 2019 • Vol. XXV, No. 1

Connect
SOLUTIONS FOR FLUID MOVEMENT, MEASUREMENT & CONTAINMENT
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GF Piping Systems
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CAST
YOUR
VOTE
Nominations are in for our annual Innovation Awards
program. Help us recognize the best-of-the-best
breakthrough solutions for the fluid handling industry.
 The deadline to vote is JUNE 30.

Cast yours now at
flowcontrolnetwork.com/innovationawards
Table of Contents | June 2019 • Vol. XXV, No. 6
Cover Series
Motors & Drives
10 Maximizing energy savings through
pump unit VFDs
By Patrick Hogg, Nidec Motor Corporation,
and Jim Sanderson, Motion Industries
Motor manufacturers offer protections to mitigate
effects of pulse width modulation so that benefits
of adding a variable frequency drive to a pump
system can be achieved.
14 Motor management:
Intelligence made easy
By Stephen Zbytowski, Eaton
10
Better motor performance and advanced monitoring
can help save energy costs, protect systems and
improve safety.
Features
16 Major causes of roller bearing failure
and prevention tools
By John Bernet, Fluke Corporation 20 23
Roller bearing reliability can be strengthened with
proactive maintenance strategies.
20 An effective IIoT entry point is through Departments

software applications
By Ron Fleissman, Emerson Automation Solutions
Purpose-built apps designed for specific assets are a
4 From the Editor
simple, cost-effective way to improve plant connectivity.
6 News & Notes
23 Case study: Cleaning with controlled
gas explosions 8 Application Corner & Quiz Corner
By Fabian Hössli, Kistler
A U.S. plant partners with an industrial cleaning company
and a blast measurement specialist for emergency
30 Trade Shows & Events
component cleaning.
31 Advertiser Index
Innovation Awards 32 FlowControlNetwork.com

26 Nominations for 2019
Read about the nominees before casting your vote at
Cover: imantsu/iStock
flowcontrolnetwork.com/innovationawards
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2 | June 2019 Flow Control

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VICE PRESIDENT & GROUP PUBLISHER
MICHAEL C. CHRISTIAN
[email protected]
EDITOR IN CHIEF
From the Editor MOLLY ROGERS
[email protected]
CONTRIBUTING EDITORS
T
AMY W. RICHARDSON
his issue, Flow Control is proud motor and VFD. You’ll also find an arti-
[email protected]
to present the nominations for our cle from Eaton’s Stephen Zbytowski who MARIE MCBURNETT
annual Innovation Awards program. talks about motor management relays [email protected]
Read about the latest breakthrough solu- and advanced monitoring. Also, Fluke GROUP ASSISTANT EDITOR
tions in fluid handling applications on Corporation’s John Bernet discusses DANIEL GADDY
page 26, and then be sure to go online causes of roller bearing failure and pre- [email protected]
and vote at flowcontrolnetwork.com/ vention strategies. COLUMNIST
innovationawards. We will close the vot- Next, read about an effective way that DAVID W. SPITZER
ART DIRECTOR
ing on June 30 and present the honorees plants can make the jump into the inter-
RYAN CARLSON
in the October issue. net of things by using
PRODUCTION MANAGER
Good luck to all of the purpose-built apps AMANDA PORTER
nominees! and software applica- [email protected]
Last month, I had the tions for specific plant DISTRICT MANAGER
opportunity to learn assets to improve con- JAY HAAS | 281-980-5831
more about a few of nectivity, help optimize [email protected]
these solutions at the processes and protect ACCOUNT MANAGER
Offshore Technology operations. Lastly, we ADDISON PERKINS | 205-463-1774

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

Jeff Jennings: Equilibar LLC | Mitch Johnson: JMS Southeast | Gobind Khiani: Fluor Canada Ltd.
Jim Lauria: Mazzei Injector Company | John Merrill, PE: EagleBurgmann Industries
Steve Milford: Endress+Hauser U.S. | Tom O’Banion: Emerson Automation Solutions
David W. Spitzer, PE: Spitzer and Boyes LLC | George Weihrauch: ABB Motors & Mechanical
Andrew Yeghnazar: Blacoh Fluid Control | Jesse Yoder, Ph.D.: Flow Research

News & Notes
Company news of AW-Lake Company, Exact Dispensing troubleshooting and light repair work.
Systems, KEM GmbH, Litremeter, There will be a crew of three on rotation
Orbital Gas Systems SignalFire Wireless Telemetry, and at all times with a service manager located
showcases new technologies Vogtlin Instruments. in Hempstead, Texas. Jim Trullinger, ser-
at open house vice manager, will be in charge of this
Orbital Gas Systems, a wholly owned New CEO at Siemens new service area.
energy subsidiary of CUI Global Inc., Oil & Gas
held a technology showcase and open Arja Talakar was appointed CEO of Siemens Ecogreen Tank Monitor
house for customers and suppliers at Oil & Gas. He is based in Houston, Texas, introduces a savings calculator
its Houston facility. The 39,000-square- the global headquarters for Oil & Gas and Ecogreen Tank Monitor introduced an
foot facility supports the growth of the its parent operating company, Siemens interactive savings calculator to help
upstream, midstream and downstream Gas and Power. Talakar was previously estimate how much money can be saved
product lines and services, including gas responsible for Siemens Saudi Arabia. He by deploying tank monitors. The Savings
metering, process control, telemetry, gas began his career with Siemens in 1996 Calculator, found on the company’s web-
sampling, environmental monitoring and as a rotating equipment and automation site, allows for the input of labor costs
biomethane systems. More than 150 systems engineer. of manually checking tank levels, plus
attendees, including midstream and the cost of run-outs that result in idled
downstream end users and service TUV SUD NEL launches JIP equipment and workers. The calculation
companies, viewed featured technolo- for oil-in-water analyzers results in an annual savings that can be
gies, including GasPT analysis units, VE TUV SUD NEL launched a joint industry compared to the cost of purchasing or
Technology sampling equipment, mercury project (JIP) to fill a significant knowl- leasing the Ecogreen Tank Monitor. Fuel
analyzer systems, Integration modules edge gap in the oil and gas industry’s distributors and suppliers of other liquids
and biomethane solutions. use of online oil-in-water analyzers to can also use the Savings Calculator to
help optimize oil and gas recovery. The determine delivery cost savings based on
ITT acquires Rheinhütte JIP will deliver a new set of regulatory cost per delivery or cost per mile.
Pumpen Group requirements for subsea produced water
ITT Inc. completed the acquisition of discharges as well as guidance for the Smith-Cooper International
Rheinhütte Pumpen Group, a designer acceptance of using online oil-in-water to merge with Anvil
and manufacturer of centrifugal and analyzers for unmanned and subsea International
axial flow pumps, from Aliaxis Group applications. It will also create a new set Anvil International, a designer, manufac-
S.A. The acquisition aligns with ITT’s of validation criteria for the use of oil-in- turer and provider of products that con-
focused growth strategies in target water analyzers for reporting purposes. nect and support piping systems, and
markets and provides the company’s This will help operators optimize their Smith-Cooper International, a global
Industrial Process (IP) segment with a production process, maximize the effi- designer and provider of pipes, valves
complementary portfolio of pump tech- ciency of oil and gas recovery and reduce and fittings, have entered into a defini-
nologies suited to corrosive, abrasive operational costs. It is intended that the tive agreement to merge. The combined
and high-temperature environments. JIP’s research work will enable the exist- company — majority owned by Tailwind
The acquisition also bolsters IP’s pres- ing online oil-in-water analyzer guidance Capital — will be a designer, manufac-
ence in Europe through enhanced pump from OSPAR, BEIS and Norsk Olje & Gas turer and provider of products that con-
engineering, manufacturing, testing and 085 to be updated and improved. nect and support piping systems with
channel-to-market capabilities. a portfolio of global brands including
Logan Industries expands AFCON, Anvil, Anvil EPS, Anvil-Strut,
TASI Group acquires ONICON services into West Texas Basic-PSA, Beck, Catawissa, Cooplok,
Measurement Solutions Logan Industries, a hydraulic repair, Cooplet, FlexHead, FPPI, Gruvlok, J.B.
TASI Group, a privately owned industrial manufacturing and rental company, Smith, North Alabama Pipe, Megawatt,
test, measurement, inspection and expanded its land rig equipment ser- SCI, Sharpe, SPF/Anvil and SprinkFLEX.
assembly business, acquired ONICON vices capabilities into West Texas. The Together, Anvil and Smith-Cooper will
Measurement Solutions, which includes new service will cover Midland, Odessa offer a comprehensive product portfolio
the ONICON, Fox Thermal, Seametrics, and the surrounding 100-mile radius, to national, regional and local distribu-
Greyline and Pulsar Process Equipment enabling Logan to offer quicker on-site tors across North America serving the
brands. The ONICON Measurement and on-call services to these remote industrial, commercial, fire protection,
Solutions companies will become part regions. Logan purchased a service energy and mining end markets. The
of the existing TASI Flow Group of com- truck outfitted with all required tools and transaction is expected to close in the
panies, which are currently comprised spares for the most common hydraulic second quarter of 2019.

Awards & NETZSCH celebrates 50th
anniversary of North
Milestones American operations Upcoming events
NETZSCH Pumps North America LLC is cel-
Armstrong Fluid Technology ebrating its 50th anniversary. As a mid-sized, Sensors Expo
recognized with British family-owned German company, NETZSCH June 25–27
San Jose, California
pump industry award manufactures machinery and instrumen-
sensorsexpo.com
Armstrong Fluid Technology’s Design tation with worldwide production, sales
Envelope Tango pump was awarded the and service. The global company began its EASA
accolade of Environmental Contribution North America operations as a one-person June 30–July 2
of the Year at the 2019 BPMA Pump office 50 years ago and has since grown Las Vegas
Industry Awards. Founded by the British to more than 180 employees for its three easa.com
Pump Manufacturers Association (BPMA) North American business units, Analyzing
in 2000, the Pump Industry Awards & Testing; Grinding & Dispersing; and ISA Energy & Water
program celebrates the achievements Pumps & Systems. NETZSCH marked the Automation Conference
of pump companies and individuals. milestone year with a gala celebration on Aug. 7–8
Judges commented on Tango pump’s May 11, 2019, at the historic SunnyBrook Orlando
isa.org
levels of efficiency and innovative Ballroom in Pottstown, Pennsylvania. FC
Parallel Sensorless Pump Control. Using
Turbomachinery & Pump Symposia
advanced design, embedded intelligence Sept. 9–12
Send news and events for consideration
and connectivity, as well as motor effi- Houston
to Molly Rogers at mrogers@
ciency exceeding the IE4 standard, Tango tps.tamu.edu
endeavorbusinessmedia.com.
pumps deliver energy savings.
Reliable Flowrox Pump Technology

For transferring, dosing and metering
● Ideal for heavy-duty applications

● 3-5 times longer hose lifetime
● Advanced rolling design
● Pump up to 80 % solids
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CE 197
SIN ASK FOR MORE: Follow us:
7
888-356-9797 / [email protected]
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FL
OW O
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www.flowcontrolnetwork.com June 2019 | 7

Application Corner
By David W. Spitzer
Part 1: Measuring under vacuum:

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

Quiz Corner What is the rule of thumb for the amount of straight run
required upstream and downstream of a flowmeter?
A. 0 diameters upstream and 0 diameters downstream B. 5 diameters upstream and 3 diameters downstream
C. 10 diameters upstream and 5 diameters downstream D. 40 diameters upstream and 5 diameters downstream
R
esponses from students in my Industrial Flow is installed. All of the answers can apply to one or more flow
Measurement seminar (and many others) would technologies and/or flowmeter designs.
indicate that the rule of thumb for installation is 10
diameters of straight run upstream of the flowmeter and 5 Additional complicating factors
diameters of straight run downstream of the flowmeter, so it The ramifications associated with not having one rule of thumb
would seem that Answer C would be correct. However, there are many. Consider that many flowmeters are installed in
Vijay kumar/iStock
is no valid rule of thumb for installation because every flow- locations where limited space does not allow for the required
meter has straight-run requirements that result from multiple amount of straight run. In such instances, flowmeter perfor-
considerations, including the flowmeter technology, flowmeter mance would be degraded so another technology and/or flow-
design and the geometry of the piping in which the flowmeter meter with shorter straight-run requirements should be applied.

Cover Series: Motors & Drives
Maximizing energy savings

through pump unit VFDs
Motor manufacturers offer protections to mitigate
effects of pulse width modulation so that benefits
of adding a variable frequency drive to a pump
system can be achieved.
By Patrick Hogg, Nidec Motor Corporation, and Jim Sanderson, Motion Industries
A
ccording to the International speed. A 50% reduction in speed, in
Energy Agency (IEA), approxi- other words, produces a 50% reduction
mately half of the electricity used in flow. The pressure or head produced,
globally is consumed in electric motors. however, decreases by the square of the
Industrial motor systems account for speed. A 50% reduction in speed results
about 70% of the manufacturing elec- in a 25% reduction in pressure.
tricity used. Because power consumption is related
In the U.S., pump systems account for to work, the relative work required is
about 40% of all industrial motor systems greatly reduced when both the flow and
electricity. The trend has been to design pressure are reduced. The power reduc-
more efficient pump systems for the high- tion is the cube of the decreased speed.
est return on energy savings. So when motor speed is reduced by 50%,
In many applications, flow and pressure the power required is (0.5)3, or 12.5% of
are regulated using one of two ways. They the required motor torque and current,
can be controlled mechanically using compared to full-speed operation. This
throttle valves or by adjusting motor is known as the Affinity Law.
speed using variable speed drives. A
throttling valve, which mechanically limits Pump matching to the VFD
the flow in a system, is both mechanically Dramatic energ y savings can be
and electrically inefficient. achieved by reducing pump speed.
The preferred way to adjust pump However, it remains critical to select
speed and flow, therefore, is typically a the correct pump for the application
variable frequency drive (VFD). The VFD based on needed flow and pressure.
electrically changes the frequency to that As always, the pump speed-torque
of an AC motor. Motor speed is directly curve must be evaluated. There are
related to frequency, while motor current mechanical limitations as pump speed
is directly proportional to the required decreases. For example, volume
torque. As the speed of centrifugal pumps may be reduced to a point where
is lowered, the required torque and motor the pump is unable to meet
current drops dramatically. system requirements.
Variable speed motors pro-
Understanding pump vide more flexibility for using a
operation using VFDs pump that meets current needs, with
In centrifugal pump operation, flow possible increases in the future. A VFD
decreases in proportion to the drop in helps improve pump life by operating

(Above) U.S. Motors
Vertical Hollowshaft As the speed of centrifugal pumps is
motor and VFD
provides flexible water lowered, the required torque and motor
flow options for a
cattle ranch in Texas.
current drops dramatically.
Courtesy of Nidec
(Left) The VFD in this below designed pressure limits. It also PWM switching waveform can affect a
system controls the provides the ability to ramp to speed, motor’s winding insulation and bearing life.
lead/lag operation,
maximizing efficiency
which reduces mechanical shock or More specifically, PWM can cause
and longevity of water hammers, and to match power motor windings to experience voltage
the pumps. to performance. spikes well above their standard voltage
Courtesy of While VFDs deserve credit for helping limits. On a three-phase AC line voltage,
Motion Industries
systems maintain peak efficiency, they for example, it takes about 8 milliseconds
also have the potential to damage the for standard sinewave power to transition
motors they drive — unless steps are from one peak to the next. PWM causes
taken to reduce their harmful effects. dramatic spikes in voltage, pulsing from
minimum to maximum in less than 0.001
Understanding the challenges millisecond, or 1 microsecond (µs).
of VFDs on motors Because these spikes exceed the limits
The challenges posed by VFDs are related of standard insulation, they can result
to the pulse width modulation (PWM) in rapid breakdown of motor insulation,
power waveform they use to modulate compared to what might be expected if
the frequency and voltage supplied to a windings did not exceed the rated maxi-
motor. That, in turn, controls motor speed. mum voltage.
In VFDs, a rectifier converts AC to a DC Wave reflection is another phenom-
voltage, and transistors (switches) — enon that can affect peak voltages and
known as the inverter section — create their effect on motor windings. Wave
pulses to output a waveform that mimics reflection is a function of the time it
a sinewave at the desired frequency. The takes a wave to rise and the length of the

bearing mount with an insulating mate-
VFDs use pulsing DC voltage to create an imitation rial, thereby isolating the shaft from the
sinewave, which has the effect of building up a bearing. If the motor will be located in a
differential charge between the rotor and stator. hazardous environment, the manufacturer
may insulate both bearings, but more
often, will insulate the coupling instead.
cable between the VFD and the motor. specifically designed to operate with a
Reflective waves that bounce back to their VFD. These motors include specially Getting to the root
source can become additive to incoming designed winding and bearing protections of the problem
waves. The longer the cable, the greater that mitigate some of the effects a PWM While motor protections like these are
the wave reflection. Reflected waveforms waveform can have on a motor. helpful, they do not address the root
can build to a point of damaging the VFD The shift to VFDs has led to the addition causes of PWM waveform damage. The
and motor. Consideration of this phenom- of inverter wire as a standard feature in fact is, manufacturers often add these
enon should be taken into account when integral horsepower random wound motors. protections because they cannot predict
the distance between VFD and the motor Electric motor design and manufacturing where, how or when these components
it controls exceeds the VFD manufac- techniques have also undergone changes will be installed.
turer’s suggested distance. Technologies to accommodate VFD applications, as well When reviewing the system as a whole,
that allow for greater distances to occur as to eliminate shaft currents. follow the manufacturer’s guidelines to pro-
in the field can be added to the system. To protect against voltage spikes that vide correctly sized wire, filters and con-
Motor windings and VFD damage are exceed their rated voltage, inverter duty duit. Refer to the manual to understand the
not the only issues affected by PWM. motors are designed for use with VFDs proper grounding requirements of the motor
Premature bearing failure can also be by typically including inverter duty insu- and VFD. The following guidelines can help
attributed to fast-rising voltage pulses. lation systems rated to handle the volt- achieve a successful design and installation
The high switching frequency inverters age spikes that occur. Insulation design (always refer to the manufacturer’s manual
used to achieve the required PWM wave- standards are regulated by the National for any additional information):
form causes capacitive energy to build Electrical Manufacturers Association
between the rotor and stator. (NEMA), which specifies the maximum VFD installation: The power cables that
If this energy is released on a path peak voltage each type of insulation must connect the VFD to the motor should be
through the motor bearings, it can cause withstand, as well as the minimum rise shielded and rated for use with a VFD.
electrical discharge machining (EDM), time for power waveforms. The manufacturer should be able to rec-
also known as fluting, which can cause According to NEMA MG1 Part 31, the ommend cables that are appropriate for
the bearing to overheat and potentially windings on VFD-enabled motors with a the system’s voltage and current limits.
fail prematurely. 600 volts or less voltage rating must pro- Most distributors of VFDs offer a product
The voltage differential between the rotor tect, at minimum, against a voltage spike of that meets these requirements.
and stator that results from use of PWM 3.1 times the rated voltage and a rise time
waveforms on a standard inverter can also greater than or equal to 0.1 µs. Motors Grounding: VFDs produce high frequency
affect an electric motor’s bearings. with a voltage rating greater than 600 noise. To reduce the damaging effects
Three-phase motors driven by standard volts must protect, at minimum, against of that noise, motors must be grounded
sinewave power have a balanced charge. a voltage spike of 2.04 times the motor’s back to the drive. That requires a braided
The PWM waveform, however, is not a rated voltage with a rise time greater than type of grounding wire that grounds the
true sinewave. Rather, VFDs use pulsing or equal to 1 µs. motor to the drive. At minimum, that wire
DC voltage to create an imitation sin- To prevent CMV, bearings on these should be of the same size as a single
ewave, which has the effect of building motors require protection that provides a power lead and be located in the power
up a differential charge between the rotor low-resistance path to ground to mitigate lead conduit. To obtain the best mitigating
and stator. Known as common mode volt- any charge buildup. This typically requires effects, installers should consider using
age (CMV), the differential charge that mounting a shaft grounding device — multiple grounding wires.
builds up between the rotor and stator either externally or internally, per local
must be mitigated through shaft ground- codes for the motor. Conduit selection: Power leads and
ing and correct system installation to For additional protection, 100-plus grounding wire should be housed in metal
avoid damaging the bearing. horsepower motors isolate one of the conduit, which should be connected to both
bearings from the motor shaft to interrupt the motor and drive without isolating either.
Protecting VFD-enabled motors circulating currents that would otherwise PVC, plastic or other insulating materials
Aware of these challenges, many motor add extra energy to the motor shaft. This are not recommended for connecting metal
manufacturers have created product lines is typically accomplished by coating the conduit to a drive or motor terminal box. If

these materials are used, the metal con-
duit carrying the power leads and ground
cable must be properly connected to the
grounding circuit.
VFDs produce high frequency noise. To reduce
The VFD manufacturer may be able to
suggest other filtering options to further the damaging effects of that noise, motors must
reduce risk. be grounded back to the drive.
For existing systems, it is harder to get
to the root causes of PWM. Still, its dam-
aging effects can often be reduced with
system add-ons, such as:
• Load reactors: These inductive
devices slow quick rise times and
eliminate high peak voltages.
• Inductive absorbers: Some damag-
ing bearing currents can be reduced
using these inductive devices.
• dV/dt filters: These filters limit the
peak voltage to a motor.
• Sinusoidal filters: Similar to dV/dt
filters, these filters include tuning
electronics that match carrier fre-
quency for best output waveform.
Conclusion
Capitalizing on the benefits of adding a
VFD to a pump system is possible when
the entire system is reviewed for the
effects of PWM power before the proj-
ect is started. To achieve the greatest
protections, it is necessary to design and
install these components as an integrated
system. Understanding both the issues
and operational requirements of a VFD
system will lead to years of successful
operation. FC
Patrick Hogg is the appli-

cation engineering man-
ager of General Industry
and Integral Horsepower
Pumping at Nidec Motor Corporation.
Jim Sanderson is a divi-

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

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

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

Features: Bearings
Major causes of roller bearing

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

(a) (b) (c) (d)
sizovin/iStock
(h)
(e) (f) (g)
Figure 1. Bearing shapes: a) deep groove ball bearing, b) angular contact ball bearing,
c) self-aligning ball bearing, d) cylindrical roller bearing, e) tapered roller bearing,
f) spherical roller bearing, g) needle roller bearing, h) thrust ball bearing
Illustrations from SKF Bearing Catalogue. Image courtesy of Solano-Alvarez, Wilberth.
(2015). Microstructural degradation of bearing steels, Fig. 2. https://www.researchgate.
net/figure/Bearing-configurations-30-a-deep-groove-ball-bearing-b-angular-contact-ball_
fig1_281127914 [accessed 29 Apr, 2019].
noise using sound detection instru- to blue. Temperatures over 400°F

ments during operation. can anneal ring and rolling element
• Peeling: Caused by hairline cracks. metals, reduce bearing capacity and
Condition consists of small areas of cause early failure. High tempera-
flaking due to insufficient lubrication tures can also degrade or destroy
or infiltration of foreign matter. lubricant.
• Spalling: Pitting or flaking away of • Pitting: Small areas of flaking or
bearing material. Primarily occurs on peeling caused by hairline cracks.
races and rolling elements. Always Condition may be caused by foreign
accompanied by an increase in matter infiltration or insufficient
vibration. Condition will continue to lubrication.
spread with ongoing operation. • Vibration: Bearing irregularities can
• Overheating: Ring discoloration of be analyzed by measuring the vibra-
rolling elements and cages from gold tions of an operating machine using
a frequency spectrum analyzer
to calculate the magnitude of
vibration and frequency distri-
bution. Test results help deter-
mine the likely cause of the
bearing abnormality.
Figure 2. Top reasons

roller bearings fail
Courtesy of
Fluke Corporation

Type Causes Clues Cures
Contamination • Foreign matter in lubrication • Denting of rolling elements • Filter lubricant

or clearing solutions and raceways • Clean work areas, tools,
• Contaminants from work areas • Vibration fixtures and hands
and dirty hands or tools
Corrosion • Condensation • Brown or red stains on rolling • Divert corrosive fluids

• Moisture elements, cages or raceways • Select integrally sealed bearings
• Broken-down or • Increased vibration followed • Use external seals for particularly
low-quality grease by wear hostile environments
• Poor wrappings • Increased radial clearance • Use appropriate bearing material
• Loss of preload in corrosive environments
Excessive loads • Bearing overload • Heaving rolling element • Reduce load

wear paths • Use bearings with
• Overheating larger capacity
• Widespread fatigue areas
False brinelling • Rapid movement of balls in a • Linear wear marks in the • Eliminate or absorb
raceway while equipment is idle axial direction at the rolling external vibration
wears away lubrication element pitch • Use lubricants containing
• Lack of rotation in the bearing • No raised edges, unlike marks anti-wear additives
prevents fresh lubricant from due to incorrect mounting
entering the bearing
Fatigue (spalling) • Overloading, excessive preload • Fracture of running surfaces • Replace bearings
• Tight inner-ring fits • Loss of small, discrete • Redesign using a bearing with
particles of material from greater calculated fatigue life,
the inner ring, outer ring or internal clearances and proper
rolling elements shaft and housing standards
• Increase in vibration and noise
• Spalling will spread with
continued operation
Fit • Tight fit: excessive loading of • Tight fit: heavy rolling-element • Make sure a proper clearance
the rolling element when wear path in the bottom of is selected to avoid fit issues
interference fits exceed the the raceway, overheating or • Refer to the manufacturer’s
radial clearance at operating an inner-ring axial crack installation guide
temperatures • Loose fit: note any generation of
• Loose fit: micro-motion fine metal particles, which
between fitted parts leaves a distinctive brown color
Improper mounting • Bearings mounted by applying • Denting • Follow specified mounting

pressure or blows to the outer • Wear instructions
race or into the housing by • Cracked rings • Train employees to ensure they
pressing on the inner ring • High operating temperatures understand the difference
• Loose shaft and housing fits • Early and premature failure between improperly and
• Excessively tight fits adequately installed mounting
• Out-of-round housings • Mount bearings with a press
• Poor finish on the bearing seat fit on the rotating ring
Lubrication • Insufficient lubrication • Overheating • Use the compatible and

• Improper lubricants • Discoloration precise amount of lubricant
• Excessive temperatures that • Excessive bearing wear • Avoid grease loss
degrade lubricant • Schedule regular relubrication
Misalignment • Bent shafts, out-of-square shaft • Overheating and • Inspect shafts and housings
shoulders, out-of-square separator failure for runout of shoulders and
spacers, out-of-square clamping • Wear path not parallel bearing seats
nuts and improper installation to raceway edges of the • Use precision-grade locknuts
due to loose fit nonrotating ring
Table 1. Causes, clues and cures for premature roller bearing failure

Premature roller maintenance tasks, roller bearings have strategies, M&R teams can further ensure
bearing failure a better chance of reaching their full poten- roller bearing reliability. FC
Learning to troubleshoot bearing prob- tial. When predictive maintenance tools,
lems is a crucial part of any maintenance such as vibration sensors, are integrated References
program. As many as 13% of industrial with computer maintenance management 1. Britannica, T. E. (2011, June 09).
motor failures happen because of bear- software (CMMS), maintenance teams can Lake Nemi. Retrieved from https://
ing failures. Moreover, 60% of equipment set acceptable boundaries for equipment www.britannica.com/place/Lake-
breakdowns involve bearing wear. operation, import and view continuous Nemi.
Most defects result from a combination readings and graph results. Additionally,
of failure modes, and each failure is usu- the system can be configured to automati-
ally due to a mixture of causes. cally trigger an email or generate a work John Bernet, a mechani-
order — should equipment exceed param- cal application and prod-
Vibration: A chief precursor eters. With cloud technology, maintenance uct specialist at Fluke
to bearing failure and reliability (M&R) teams can view data Corporation, works with
Usually, before bearings fail, the problem in real time from anywhere, any time. customers from all industries to help them
appears in the form of vibration. For Premature roller bearing failure can successfully implement their reliability pro-
example, roller bearings will cause vibra- affect business, the environment and grams. He is a former U.S. Navy nuclear
tion each time they pass over a damaged personnel — should the bearing cause power plant electrician and has more than
or pitted roller bearing race. Without being an explosion. Even the most comprehen- 30 years of experience in the maintenance
harmful or invasive, vibration analysis sive maintenance program can result in and operation of commercial machinery.
provides the most detail about what is undetected faults, leading to unexpected Bernet holds a Category II Vibration Analyst
happening inside machinery by detect- failures. However, through proper care and certification and is a Certified Maintenance
ing minuscule changes in acceleration, with the help of proactive maintenance Reliability Professional (CMRP).
direction or velocity that may indicate
bearing wear, installation error or other
mechanical problems.
Wireless condition monitoring vibration
sensors installed on a bearing housing
can provide maintenance teams with
actionable data. Technologically advanced
tools can help further ferret out more
complex issues that might show up in the
overall vibration analysis. It can then be
used to decide whether additional analy-
sis is required and if relubrication, repairs
or replacements are needed.
Infrared (IR) thermography can also be
used for oil analysis to discover if wear
particles or other contamination-causing
issues are present in the roller bearing.
Thermal imaging sensors can be set in
place to monitor equipment condition
safely. Measurements are taken from
a distance and uploaded to the cloud,
where technicians can view them on a
smart device, such as a mobile phone,
tablet or computer. The data can then
trend temperature changes over time and
help determine if bearings are operating
optimally or headed for a breakdown.
Boost roller bearing life

using PM and PdM strategies
Fortunately, by carrying out preventive

Features: Control & Automation
An effective IIoT entry point

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

to engineers, requires stepping up to data transfer from Coriolis flowmeters,
some form of digitizing and interconnect- for example, within the plant. This means
ing the plant as well. Not only because data can be collected securely from the
of the digital background of the younger cloud without physically having to check
generation of workers, but also because the meter.
not all the jobs left by the older generation
will be backfilled, meaning there will be Software applications
more work to do for fewer people. To meet provide solutions
the needs of the workload and to ensure With data diodes and secure gateways
the safety and productivity of the plant, in place on metering equipment, it then
new systems need to be put in place. becomes a matter of accessing the gate-
way to collect the data. Several large
Data security first technology and manufacturing companies
One of the biggest concerns that manu- are seeing the value of apps — software
facturers have about adopting digital applications that can live on a desktop,
automation technology is security. What laptop, tablet or phone for easy access.
happens when information is shared These apps, just like the ones found on
wirelessly? What about cloud storage? a smartphone, allows instant access to
Will the data gathered from meters and data from every designated device.
transmitters be safe or will it be vulner- It would be a nearly impossible task
able to hackers? With recent reports for engineers and technicians to sift
about data breaches and datamining, through the reams of data that meters
the risk of data loss to outside entities generate; however, well-conceived
is certainly real. designed software can instantly sift
A surprisingly simple solution to miti- through and compile data into action-
gating that risk is the use of devices able information, such as:
metamorworks/iStock with data diodes that establish a uni- • The health of the meters
directional security gateway. Combining • How much is flowing through
mind, the conversation becomes more chal- this with appropriate protocol translations each meter
lenging but not impossible. It requires careful constructs simple systems that allow for • Which meters are not performing
planning and research to determine the best the highly secure transfer of data from within set parameters
options for modernizing an older plant. gateways that talk directly to sensors, • An alert that warns of critical issues
such as WirelessHART gateways found requiring immediate attention
The next generation on many of today’s newer flowmeter
While conversations around digitizing transmitters. This capability relieves a considerable
operations are happening, there is another Using these types of devices allows a burden on technicians and engineers,
important development that has an impact plant to establish a secure perimeter for because there may not always be an
on the decisions involving IIoT: changes in
the workforce.
A significant segment of workers are
reaching retirement age, and when they
Courtesy of Emerson Automation Solutions
leave, they will take with them decades

worth of skills and knowledge that cannot
be easily or quickly taught to new hires.
Also, many younger workers are digital
natives and are accustomed to having
data at their fingertips on digital devices.
This environment has contributed to a
growing skills gap in manufacturing that
will have a significant effect across indus-
tries; it is predicted that millions of jobs
will remain unfilled by 2025.
Attracting and integrating the new gen-
eration of plant workers, from technicians

option to quickly glean changes hap- and every meter in the field. This saves Connected plant benefits
pening in a meter unless they are big time and money and ensures safer work- Greater plant connectivity ensures that
enough to cause a noticeable problem ing conditions for personnel. data can be acted upon immediately.
down the line. A purpose-built app for each specific Relevant information is culled and pushed
Adding to that benefit is knowing which asset — displaying on a dashboard and out to the digital dashboard so everyone
meters are not functioning correctly sending critical alerts when needed — is with access can view it — not just in
based on what the app displays, mean- an easy and cost-effective way a plant terms of the health of the meters, but
ing users no longer need to check each can make forays into IIoT. also the state of production.
Using a collection of easy-to-deploy
applications optimizes productivity and
ensures greater accuracy in measurement.
This has benefits for not only plant opera-
tions, but also for custody transfer and for
the accurate automated measurement of
additives that can be adjusted based on
whether readings fluctuate. Furthermore,
Precision Mass Flow Measurement recorded and stored data provide an audit
An ONICON Brand trail of plant operations that can be used to
generate reports needed to meet regula-
tory and customer compliance standards.
A winning proposition:
Software applications
In this data-driven world, a competitive
advantage is gained by those who can
harness and act on information the fast-
est. The ability to quickly and easily distill
data and translate it into clear, useful
and directly actionable information is key.
Leveraging the full potential of available
intelligence from plant assets can often
seem like a daunting proposition. That’s
where well-designed software applications
come into play. Software applications offer
intelligence, security, scalability and imme-
diate insights, which in turn will allow for
peak process optimization and protection
of plant operations and assets. FC
Ron Fleissman is a software product mar-

keting manager at Emerson Automation
MODEL FT4X
Solutions. He has extensive experience
THERMAL MASS FLOW METER working with technology and software
• Accuracy compliant startups in New York City. Fleissman
BLM 3175 & API 14.10 graduated from Syracuse University with
• Data Logger with 7-year history
• Gas-SelectX® gas selection menus a degree in political science.
• Advanced DDC-Sensor™ technology
• CAL-V™ in-situ Calibration Validation
• No additional pressure or
temperature compensation GET A FREE QUOTE
• Direct mass flow measurement MORE For more on control
• Low pressure drop foxthermal.com/quote ONLINE and automation, visit
[email protected] • (831) 384-4300 flowcontrolnetwork.com

Features: Cleaning & Safety
Case study: Cleaning with Figure 1. Bang&Clean’s cleaning

process has been used in
controlled gas explosions

industries where fuel-fired
energy and power generation
plants are in operation.
All images courtesy of Kistler
A U.S. plant partners with an industrial cleaning company and a

blast measurement specialist for emergency component cleaning.
By Fabian Hössli, Kistler
W
hen using controlled gas explo- components and avoided downtime. (BAM). Certified experts only prepare the
sions to clean industrial Another advantage: Plant components explosive gas mixture a few moments
plants, cleaning is carried out continue to operate during the cleaning before the detonation in the boiler to
while the plant is running and in com- process to avoid shutting down the plant, ensure plant and personnel safety.
pliance with strict safety regulations. thus saving costs.
This process has been used in almost Application: Emergency
every sector of industry where fuel-fired How it works cleaning near a nuclear
energy and power generation plants are With Bang&Clean’s explosive cleaning power plant
in operation. Examples include waste-fed system, first, the specialists introduce a Most of the company’s cleaning system
heating plants, biomass power stations water-cooled lance — prefitted with a deployments are planned well in advance,
and hazardous waste incineration plants, special bag — through the boiler’s doors but there are occasional emergencies or
as well as chemical and pharmaceutical or portholes near the heating surface to special assignments with only a few days or
facilities. Ash and slag deposits must be be cleaned. The bag is inflated with a hours notice. This is what happened when a
removed regularly from plant components combustible gas mixture, which is then U.S. plant operator contacted the company
such as boilers, catalytic converters and ignited to cause an explosion. This gener- with a request to clean its components.
reactors; otherwise, performance will be ates a highly dynamic pressure wave and “That really was a very special case,
reduced, faults will occur and operators causes vibrations in the pipes and walls because our customer’s facility was in the
will be faced with high outage costs. that dislodge deposits of ash and slag. immediate vicinity of a nuclear power plant,”
The Bang&Clean system for cleaning Throughout the process, the top priority said Markus Bürgin, founder and managing
with controlled and dosed explosions was is safety for people and machines. The director of Bang&Clean Technologies AG.
developed in 2000 for cleaning indus- cleaning equipment is CE-compliant, and “To obtain approval for cleaning the plants,
trial plants and components. Benefits it is inspected by the German Federal our customer had to submit advance proof
include long service lifetimes for plant Institute for Materials Research and Testing that the cleaning method was safe.”

Bang&Clean did not have the measure-
Plant components continue to operate during ment expertise required to provide the
the cleaning process to avoid shutting down the necessary proof, so Bürgin called in a
cooperation partner, Kistler, a company
plant, thus saving costs. with application expertise in blast pres-
sure measurements.
“When we received this inquiry from
Boiler
the U.S. at such short notice, we imme-
diately realized that we couldn’t handle
this project unless we called in the mea-
Equipment surement technology specialists from
Winterthur [Switzerland],” said Bürgin.
Ignition Given the time pressure, Bang&Clean
and Kistler needed to prepare a mea-
surement campaign within the short-
Lance
est possible time. Philipp Schenkel
and David Weber, Kistler’s develop-
ment engineers, provided support and
advice for the team headed by Bürgin
throughout the project. To ensure cor-
rect measurement of the pressure val-
ues required, they opted for a relatively
Figure 2. Bang&Clean’s cleaning process simple test setup in an experimental
gallery at Lungern.
subscribe today.
Deepwater
Pipelines Technology for offshore
oil and gas operations
Also Inside
Accuracy and traceability

of flow measurement
How the floating ball

valve works
Condition monitoring of
heat-transfer pumps
APRIL 2019 • Vol. XXIV, No. 4

flowcontrolnetwork.com/subscribe

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

Innovation Awards
Badger Meter
Dynasonics TFX-500w Ultrasonic
Clamp-on Flow Meter
2019 The TFX-500w Ultrasonic Clamp-on Flow Meter mea-

sures water flow bidirectionally in pipes 10 inches or
Innovation Awards Nominees smaller. By clamping on the outside of the pipe, the
ultrasonic meter installs without cutting or tapping the
Each year, Flow Control accepts nominations for its pipe. Designed for noninvasive, ultrasonic transit time
Innovation Awards program to demonstrate how the flow measurement, the meter accurately determines
fluid handling industry is keeping up with evolving the rate, total and velocity of water flow. With a large,
technology. The entries recognize the importance easy-to-read display, the meter provides Modbus RTU
that companies place on continued improvement and and BACnet MS/TP connectivity and integrates with
investments in research and development for innova- the Badger Meter BEACON and AquaCUE Advanced
tive solutions. Read about the nominees here, and then Metering Analytics (AMA) cloud-based software
go to flowcontrolnetwork.com/innovationawards to cast suites. The meter can be programmed through the
your vote for the 2019 honorees. The deadline to vote front panel or USB cable using SoloCUE Flow Device
is June 30. Manager software.
The TFX-500w meter can be retrofitted in existing
installations. It has no pressure head loss, no contact
with internal liquid and no moving parts to maintain.
Emerson
Micro Motion 4200 2-wire Transmitter
The Micro Motion 4200 Coriolis 2-wire flow and density transmitter offers up to a 4-inch
line size to accommodate larger flow rates that require a 2-wire Coriolis meter. Smart
Meter Verification is standard, along with zero verification. Real-time clock facilitates
troubleshooting by time-stamping process data, audit trails and Smart Meter Verification
reports. The touch control display provides ease of use and lowers commissioning time.
The transmitter also offers a remote mount option.
The 2-wire Coriolis meter uses the existing wiring without the need to run additional
wiring, scaffolding, conduit, AC panels and transformers, reducing complexity, length of
time and cost for retrofit or plant expansion projects. The transmitter housing is engi-
neered to provide easy access for installation, mounting and maintenance. The intuitive
interface allows full commissioning, configuration and operations through the display.

Endress+Hauser
Proline Prowirl F 200
Proline Prowirl F 200 is a multivariable vortex flowmeter for inline wet steam mea-
surement, primarily designed for steam, gases, liquids and cryogenic fluids. With
loop-powered technology, it enables seamless integration into existing infrastruc-
tures. Heartbeat Technology ensures process safety.
The Prowirl F measures volume flow, mass flow, corrected volume flow, energy flow,
heat flow difference, temperature and pressure. It is able to measure steam quality for
improved energy efficiency as well as plant and personnel safety. It offers operational
safety in hazardous areas and can be used in Safety Instrumented Systems (SIS) in
accordance with IEC 61508 and IEC 61511. It features lifelong calibration when used
in nonabrasive and noncorrosive media due to its patented capacitive sensor. The new
design allows flexible orientation and installation of the pressure transmitter.
EXAIR Corporation
No Drip External Mix Narrow Angle Flat Fan Atomizing
Nozzle 1/8 NPT
The No Drip External Mix Atomizing Spray Nozzles positively stop liquid flow when com-
pressed air is shut off. They are ideal where no post-spray drips are permissible. Three
liquid patterns are available: round, narrow angle flat fan and wide angle flat fan pat-
terns. They are used for pressure-fed applications where precise liquid flow is needed.
External nozzles can be used on liquids up to 300 centipoise. The newest 1/8 NPT
versions come in 5 different flow rates.
EXAIR’s no-drip liquid air nozzles use the supply air to operate the liquid valve and
create the atomized liquid pattern. This eliminates the separate pilot line and the addi-
tional compressed air required to operate the liquid valve. Air and liquid flows adjust
independently without drips, which conserves resources and chemicals or coatings.
Fluid Components International (FCI)

ST80 Series Thermal Mass Flow Meter
The ST80 Series Thermal Mass Flow Meter featuring Adaptive Sensor Technology (AST)
is a rugged thermal dispersion technology air/gas mass flowmeter that combines feature-
rich electronics with application-matched flow sensors. It features a robust transmitter
enclosure and a broad selection of process connections for long service life and ease
of installation. The transmitter’s extensive and flexible I/O capabilities ensure a match to
current and future DCS, PLC, SCADA, recorder or alarm system. The standard transmitter
comes with multiple outputs: two NAMUR NE-43 compliant 4-20 mA analog outputs,
HART (v7) and Modbus, and a USB port plus FCI software for PC interfacing.
AST is a hybrid drive that combines both constant temperature (CT) and constant
power (CP), plus a CP-only mode, for two field-changeable measuring techniques in
one flowmeter.
Fluke Corporation
Fluke 710 mA Loop Valve Tester
The 710 mA Loop Valve Tester features preconfigured valve tests for reliable, repeat-
able testing. The built-in routines include: manually changing the mA signal and
viewing the HART position and pressure variable information; full range ramping of
the mA signal from 4 to 20 to 4 mA while recording the 0-100-0 percent position
or the pressures applied that move the valve from 0-100-0 percent. It also includes
stepping the mA signal on the input to the valve in steps and evaluating the valve’s
response to the mA input changes.
Speed tests determine how fast the valve can open or close, and bump and partial stroke
tests help test valves over a portion of their range so they can be tested in a live process.

GF Piping Systems
Signet 9950 SmartPro Dual Channel Transmitter
The Signet 9950 SmartPro Dual Channel Transmitter offers multiple measurement
readings in one transmitter. It allows for automatic pH glass impedance measure-
ment, setting of broken glass detection from 1 to 2000 megaohms and reading of
data stored in all Signet DryLoc pH/ORP electrodes.
The new Conductivity Module allows the 9950 to monitor two different conductivi-
ties with a single module. The Modbus Output Module provides secondary mea-
surements such as temperature from pH or conductivity/resistivity measurements,
as well as totalizer values for flow. New software enhances the derived function
measurements. It can now calculate the sum, difference or ratio between two similar
measurements or, for conductivity or flow measurements, determine efficiencies in
reverse osmosis systems. It also provides the ability to mix and match secondary
measurements in the calculations.
Ham-Let
IoTH800 Smart Valve
The Internet of Things H800 Smart Valve (IoTH800) features constant monitoring,
management and control of position/state indication, pressure, flow, humidity and
temperature. Due to its array of sensors and capabilities, it can be activated by trig-
gering scenarios such as downstream pressure drop (line burst), high temperature
(fire) or vibration, simultaneously sending an alert to the control room.
The IoTH800 is compatible with a range of industry 4.0 standards (e.g., Modbus,
LoRa, BLE), easing interoperability with an existing system. Integrating with IoT cloud
platform allows immediate response for safety events, machine learning and opti-
mization, machinery and equipment protection and device tracking. As an all-in-one
product, the IoTH800 Smart Valve eliminates possible leakage sources cause by
other sensors and instrumentation used with a regular valve.
KROHNE Inc.
OPTISONIC 7300 Biogas Ultrasonic Flowmeter
The OPTISONIC 7300 Biogas Ultrasonic Flowmeter — for the measurement of dry
and wet (raw) biogas with variable composition — features a pressure sensor, along
with the standard temperature sensor, that can be ordered optionally and comes
mounted on the flow tube. Combined with the integrated flow computer, the addition-
al sensor provides advanced biogas measurement. A temperature sensor in combina-
tion with the measured velocity of sound enables direct measurement of methane
content via calculation of the molar mass. Using an additional pressure sensor, it can
provide calculation of gas flow volume to standard conditions.
The biogas flowmeter can be used for any gas flow measurement, including vent
gas applications in oil and gas production. The integrated sensor options simplify
installation, while the on-board flow computer allows the output to be set to a vari-
able, e.g., methane content.
L.J. Star Incorporated

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

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

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

Vanguard WirelessHART Gas Detector Version 1.2
The Vanguard WirelessHART gas detector can monitor the presence of toxic or com-
bustible gases for approximately five years without a battery replacement. Version
1.2 incorporates new features including more mounting options, more intuitive con-
figuration and access to diagnostics. It features an option for interchangeable sensor
heads, which makes it easier to monitor different gases at different times, a new
sensing head for carbon monoxide and installation options that do not require hot
work permits, including magnetic mounting and adjustable clamp mounting.
Expanded temperature operating range and enhanced stability across temperature
ranges enables performance in extreme temperature conditions. Minimal zero shift
with changing ambient temperature reduces the chance of false alarms and provides
faster gateway connections. Updated WirelessHART commands allow quicker con-
nectivity to networks and system commissioning.
VorTek Instruments
VorCone Meter
The VorCone Meter is a robust steam quality and mass flowmeter. It is a hybrid of the
vortex and cone meter designs. The combined use provides more information. With
two unknowns, i.e., steam quality and total mass flow, cross-referencing the two
primary meter signals produces the information to meter the quality and flow rate
in real time. The meter also has the option of a cone meter pressure field analysis
verification system.
Combining two metering subsystems produces two different primary signals, allow-
ing the production of two outputs, depending on the application. In single-phase
applications, the VorCone can output the mass flow and fluid density. In two-phase
flow, such as saturated steam, it can output steam quality and steam vapor flow.

Trade Shows & Events
EXHIBITION SCHEDULE
Image courtesy of FC staff

Sun., June 30, 12:30–5 p.m.
Logo courtesy of EASA

Mon., July 1, 12–4 p.m.
Tues., July 2, 9 a.m.–12 p.m.
easa.com/convention
EASA 2019 spotlights

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

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Flowrox .......................................................................................... 7 Sage Metering .............................................................................. 19
Fox Thermal ................................................................................. 22 Spitzer and Boyes LLC .................................................................. 24
GF Piping Systems ....................................................................... IFC WEFTEC .....................................................................................IBC
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Featured
content
FlowControlNetwork.com
@FLOWCONTROL_MAG
Courtesy of ABB
Case study: Condition

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

ow.ly/Uest50t9bXD WHAT'S ON FACEBOOK
Consider components and

features when selecting the
correct #pipeline ball #valve
for isolation, control, general
service and severe service Functionality and seating
applications | @FisherValves technology for floating
ow.ly/g9YH50rjVz2 ball valves
A typical floating ball valve
Rotating buoyancy modules seals off the line pressure
can help manage and mitigate using soft seats.
risks associated with buckling
bit.ly/2LvI1T4
of high-temperature
subsea pipelines.
ow.ly/MUnJ50pxbdG
@TrelleborgGroup
Facebook Twitter LinkedIn
facebook.com/flowcontrolmagazine @flowcontrol_mag linkedin.com/groups/4068011/profile
32 | June 2019
Do you have
instant visibility
into your flow
meter health
across your
entire plant?
The PlantwebTM Insight Coriolis application

allows you to reduce manual inspections of
your Micro MotionTM Coriolis meters by
providing continuous, consistent, reliable and
actionable asset data, uploaded to an easy to
read dashboard.
• Meter health in real-time
See which meters have issues and what actions
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• Status at a glance
Instantly see the status of your meters on one
PLANTWEBTM INSIGHT
CORIOLIS APPLICATION
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Better prioritize maintenance and avoid and provides instant access to
potential safety hazards actionable diagnostics.
For product information:

www.Emerson.com/Plantweb-Insight
The Emerson logo is a trademark and service mark of Emerson Electric Co. ©2019 Emerson Electric Co.

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Trade Show Preview

Roller bearing failure

JUNE 2019 • Vol. XXIV, No. 6

Automating custody transfer

Ultrasonic ﬂowmeters for

JANUARY 2019 • Vol. XXV, No. 1

9950 Dual Channel Type 586 Pressure

Reconﬁgure valve function

 The deadline to vote is JUNE 30.

20 An effective IIoT entry point is through Departments

Innovation Awards 32 FlowControlNetwork.com

2 | June 2019 Flow Control

products solutions services

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

and vote at flowcontrolnetwork.com/ vention strategies. COLUMNIST

these solutions at the processes and protect ACCOUNT MANAGER

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

EDITORIAL ADVISORY BOARD

4 | June 2019 Flow Control

6 | June 2019 Flow Control

Reliable Flowrox Pump Technology

● Ideal for heavy-duty applications

www.flowcontrolnetwork.com June 2019 | 7

Part 1: Measuring under vacuum:

8 | June 2019 Flow Control

www.flowcontrolnetwork.com June 2019 | 9

Maximizing energy savings

10 | June 2019 Flow Control

www.flowcontrolnetwork.com June 2019 | 11

12 | June 2019 Flow Control

Patrick Hogg is the appli-

Jim Sanderson is a divi-

www.flowcontrolnetwork.com June 2019 | 13

14 | June 2019 Flow Control

www.flowcontrolnetwork.com June 2019 | 15

Major causes of roller bearing

16 | June 2019 Flow Control

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

Figure 2. Top reasons

www.flowcontrolnetwork.com June 2019 | 17

Contamination • Foreign matter in lubrication • Denting of rolling elements • Filter lubricant

Corrosion • Condensation • Brown or red stains on rolling • Divert corrosive fluids

Excessive loads • Bearing overload • Heaving rolling element • Reduce load

Improper mounting • Bearings mounted by applying • Denting • Follow specified mounting

Lubrication • Insufficient lubrication • Overheating • Use the compatible and

18 | June 2019 Flow Control

Boost roller bearing life

www.flowcontrolnetwork.com June 2019 | 19

An effective IIoT entry point

20 | June 2019 Flow Control

leave, they will take with them decades

www.flowcontrolnetwork.com June 2019 | 21

Ron Fleissman is a software product mar-

22 | June 2019 Flow Control

Case study: Cleaning with Figure 1. Bang&Clean’s cleaning

controlled gas explosions

A U.S. plant partners with an industrial cleaning company and a

www.flowcontrolnetwork.com June 2019 | 23