NOVEMBER/DECEMBER 2021 | piprocessinstrumentation.

com

Utilizing
MULTIVARIABLE
MEASUREMENT
Reduce installation and maintenance
costs while gaining process insights.
General principles of
flowmeter calibration
Page 18

Radar versus ultrasonic sensors:

Fit-for-purpose technology
Page 22

Maximizing return on investment

from your process analyzer
Page 24
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 INSIDE
NOVEMBER/DECEMBER 2021 | VOL 27 | ISSUE 10

COVER STORY: MULTIVARIABLE MEASUREMENT

12 Utilizing multivariable measurement
Reduce installation and maintenance
costs while gaining process insights.

FEATURES

16 Meeting challenges for deep-sea

gas production
Subsea flowmeter solutions can help
mitigate risks before they become severe.

18 General principles of
flowmeter calibration

12 For flowmeters, there are considerations

such as accuracy, repeatability, methods
of calibration and calibration fluid to
ensure a correct and transferable
cover: Photo by Kay Gibbs Photography
courtesy of VorTek Instruments calibration is performed.

DEPARTMENTS
22 Q&A: Radar versus ultrasonic
sensors: Fit-for-purpose technology
Comparing the advantages and
disadvantages can help you find
4 Editor’s Note the best solution for reliable
6 Industry News level measurement.

8 Application & Quiz Corner

10 Product Focus: New Products 24 Maximizing return on investment
from your process analyzer
16 Process analyzers are a significant
30 Product Focus: Gas Instrumentation monetary investment, but they have
major potential to improve production
31 Advertiser Index outputs and reduce downtime.
32 Piprocessinstrumentation.com
28 Maximize machinery life with
lubrication and IIoT
Instrumentation such as sensors,
Facebook
facebook.com/PIprocessinstrumentation differential pressure switches and
flowmeters should be considered
Twitter
twitter.com/pi_processinst when evaluating ways to leverage IIoT
for lubrication management.
LinkedIn
linkedin.com/showcase/pi-process-instrumentation

Online
piprocessinstrumentation.com 22
2 P.I. PROCESS INSTRUMENTATION | NOVEMBER/DECEMBER 2021
 The Measurement of Process Parameters

EDITOR'S NOTE CONTENT

Publisher Jim Semple
[email protected]
Chief Editor Jesse Osborne
[email protected]
t is hard to believe that we in process instrumentation — was once Managing Editor Molly Rogers

I are already closing in on the

end of year. It seems like it
was just yesterday that our
again a success.
This year’s winner, as selected by
P.I. readers through an online voting
[email protected]
Content/Video Specialist Daniel Gaddy
[email protected]

team was putting the finishing touches process, was Swagelok’s Gas Distribu- Columnist David W. Spitzer
on this brand’s transition from Flow tion Program, which, according to the Art Director Ryan Carlson
[email protected]
Control to P.I. Process Instrumentation in company, “helps industrial facilities Production Manager Shirley Gamboa
time for the start of 2021. enhance safety and reduce downtime [email protected]
And as 2021 heads toward its end, I via a complete suite of services and
believe that the first year of P.I. Process subsystems designed to fully optimize ADVERTISING
Instrumentation has been a successful one. critical gas distribution systems.” District Manager Jay Haas
We have remained steadfast in our Companies receiving honorable men- 281-980-5831 | [email protected]

commitment to delivering industry- tion accolades this year were Hawk Account Manager Lisa Williman
518-322-6691 | [email protected]
leading content to our audience. And Measurem ent, Bedro ck Automa-
we have done so by featuring edito- tion, Emerson, Endress+Hauser, and MARKETING
rial content from subject matter ex- Brooks Instrument.
perts at industr y leaders such as P.I.’s multimedia efforts, meanwhile, Digital Operations Manager Mary Beth Romano
Emerson, Endress+Hauser, Swagelok kicked off in earnest in 2021, highlighted Digital Product Director Nick Phillips
and TÜV SÜD National Engineering by video conversations with subject Audience Development Manager Anna Hicks
Laboratory. matter experts from Sierra Instruments,
We were also happy to add new au- AW-Lake and SIKA USA. Be sure to keep
CORPORATE
thors and companies to our content an eye out for an increasing amount of CEO Chris Ferrell
mix this year — including Ryan Ben- video content on our website in 2022 — CRO/CMO June Griffin
nett of VorTek Instruments. Bennett, this is one of our editorial priorities for COO Patrick Rains
who authored the cover story for this the coming year. Chief Administrative and Legal Officer Tracy Kane
issue on the topic of multivariable Overall, 2021 will go down as a suc- EVP/Industrial Group Mike C. Christian
measurement, also wrote the cover cessful year for P.I. And I am looking for-
story for the January 2021 issue of P.I. ward to what is to come in 2022. A big
that focused on steam measurement. thank you goes out to everyone at En-
P.I. Process Instrumentation (print ISSN 2694-4545; digital ISSN 2694-4553) is
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Todd Loudin, Flowrox | Bob Steinberg, Sage Metering | Jeff Jennings, Equilibar LLC |
Mitch Johnson, JMS Southeast | Steve Milford, Endress+Hauser U.S. |
John Merrill, PE, EagleBurgmann Industries | George Weihrauch, ABB Motors & Mechanical |
David W. Spitzer, PE, Spitzer and Boyes LLC | Jesse Yoder, Ph.D., Flow Research

4 P.I. PROCESS INSTRUMENTATION | NOVEMBER/DECEMBER 2021

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The Measurement of Process Parameters

 INDUSTRY NEWS
NOVEMBER/DECEMBER 2021 THE LATEST NEWS & EVENTS FROM AROUND THE INDUSTRY piprocessinstrumentation.com

COMPANY NEWS
KROHNE highlights OPTIMASS products,
TSS 7000 and more at PROCESS EXPO 2021
KROHNE Inc. highlighted a range of innovative
flowmeters for food applications at PROCESS
EXPO 2021, which took place November 2–5
in Chicago. KROHNE OPTIMASS Coriolis
mass flowmeters and the OPTISENS TSS
7000 were on display.

Courtesy of Endress+Hauser
The KROHNE OPTIMASS Coriolis mass
flowmeters are ideal for all process and cus-
tody transfer applications. Measuring mass,
volume flow, density and concentration of
liquids and gases, OPTIMASS is available
in several designs, from twin bent to single
straight tube. All OPTIMASS flowmeters
provide continuous flow measurement, even
Endress+Hauser and ISA collaborate to offer with entrained gas of up to 100% (EGM). This
makes them ideal for dairy milk receiving,
extended training services mayonnaise and shortening with up to 20%
Endress+Hauser and the International Society of Automation (ISA), a nonprofit profes- entrained nitrogen (N2), and ice cream over-
sional association for leaders in industrial automation, announced their current and future run measurement applications.
collaboration efforts for training and certification. ISA will provide select certified training The OPTIMASS 1000 is designed with a
courses in conjunction with Endress+Hauser’s instrumentation training courses, with these close-coupled twin tube configuration with an
courses offered on-site at Endress+Hauser’s process training units (PTUs) across the U.S. optimized flow splitter, manufactured to be
With the goal of advancing training of process industry personnel, Endress+Hauser highly durable and capable of handling flow
has designed and built 11 PTUs in the U.S. These full-scale, working process units rates, even in the face of pressure fluctuations.
offer hands-on experience with the types of configurations, operations, diagnostics and The KROHNE OPTISENS TSS 7000, a total
troubleshooting found in real-world process plants. suspended solids sensor for hygienic applica-
With this strategic collaboration, ISA brings its advanced expertise in controls, valves, tions, was also on display. The sensor comes
drives and other areas outside the Endress+Hauser portfolio to more students and in a with Tri-Clamp or VARIVENT connection and
real-world setting. ISA will send a representative to the Endress+Hauser PTUs to teach is particularly suitable for concentration mea-
the material with a seamless, holistic approach. This provides a world-class, one-stop- surement in milk separation, fruit processing
shop for training where learners can advance their technical education, eliminating the and other food and beverage applications.
need for training from multiple vendors. However, it is also ideal for hygienic con-
Endress+Hauser and ISA will focus on providing training for Level 1 certification, centration measurement of other process
which confirms that technicians possess a vast knowledge with respect to calibration, industries (e.g., for monitoring steam and
maintenance, repair and troubleshooting. cooling water circuits).
Endress+Hauser and ISA have co-developed an online assessment tool for cus-
tomized training. The assessment generates a report highlighting personnel strengths Webtec digital pressure gauge now offers
and knowledge gaps for an organization. From there, representatives work with these data-logging capability
organizations to create a training plan tailored to their specific needs. This online tool The HPM110 digital pressure gauge from
will be offered through both the ISA and Endress+Hauser websites in 2022. Webtec is now available with a USB interface to
facilitate data logging. This optional version with

6 P.I. PROCESS INSTRUMENTATION | NOVEMBER/DECEMBER 2021

real-time clock records both current measured is made to solve difficult applications such Beamex adds pressure pumps to its
pressures, as well as the minimum and maxi- as steam applications and is approved by webshop portfolio
mum values. Users can transfer the stored data ASME spec for steam boilers and genera- Beamex provides products and services for
to a PC or laptop in CSV file format, where they tors. The integral isolating ball check valves companies to streamline and digitalize their
will see a time and date stamp against recorded not only make this the safest sight glass on calibration process. Last year, Beamex opened
pressures. Such data sets are particularly useful the market but also provides instant glass its U.S. webshop with spare parts and acces-
for trend analysis or if there is a specific system field replacement without complicated isolat- sories for its line of calibrators. Now, users can
event that requires investigation. ing procedures from the process fluid. The purchase Beamex PG pressure pumps. Bea-
Webtec’s HPM110 digital pressure gauge true redundancy of the ACURAGE provides mex calibration pressure pumps can generate
offers the continuous monitoring of oil, gas, full functionality even in a power failure mode, pressure and vacuum while calibrating pres-
water and other pressure media in mobile which is inevitable in critical level monitoring sure instruments. The Beamex webshop acts
equipment, industrial hydraulics, compressors applications. The ACURAGE is ideal for a wide as a useful resource to better understand the
and process control systems. This hand-held range of chemical and petrochemical appli- range of spare parts and accessories available.
device, which weighs just 500 g, provides an cations such as boiler rooms, condensation Users can also confirm component compat-
economical solution to monitoring pressure tanks, storage tanks and surge tanks. ibility, view instruction manuals, a pressure
and peak pressure. Featuring a back-lit visual fittings guide, and utilize the comprehensive
display for simple operation, the screen simul- FCI's Multipoint Flue Gas Flow Meter earns search functions of the site. The webshop
taneously displays information that includes TÜV certification for AMS/QAL1 compliant can be browsed via a smartphone, tablet or
actual pressure, peak pressure, battery level continuous emissions monitoring desktop interface without the need to create
and the measurement units selected. Buttons The MT100 Series Multipoint Mass Flow Me- an account. In addition to hand pumps and
on the front panel are used to make, adjust ters from Fluid Components International (FCI) pressure generators, shoppers can also pur-
and clear settings accordingly. The HPM110 feature proven thermal dispersion flow sensing chase kits containing all the necessary parts
has a maximum system pressure of 600 bar technology. This advanced, next-gen meter and accessories for each pump, as well as
(8700 psi) for fluids in the temperature range was designed specifically for flue gas flow carrying cases designed for convenient storage
of -20°C to 80°C, while accuracy is ±0.5% monitoring in large stacks, ducts, chimneys and ease of transport.
at full scale. Installation in any orientation is and pipes. It accurately monitors and reports
also possible (if required) using a standard test the flow rate and/or the totalized flow of all NewTek protects position sensors in isolation tubes
point, or via permanent system connection. No gases and mixed gas compositions, including NewTek offers its Linear Variable Displacement
electrical connections are necessary as the hot, moist, aggressive and dirty flue gases Transducers (LVDTs) in an isolation tube format
plug and play HPM110 is battery-operated. emitted by industrial processes. to ensure the highest reliable displacement
The repeatable and reliable MT100 Series feedback of hydraulic/non-hydraulic pumps
Hawk Measurement and Bliss Americas Multipoint Mass Flow Meter is now TÜV-cer- and valves. The isolation tube protects the
collaborate to release single-chamber tified as AMS compliant with EN15267-3 with LVDT core from pressurized environments and
sight glass with GWR QAL1 and EN14181 (2015). Certification by fluids when the sensor measures pump flow
Hawk Measurement (HAWK), a global leader TÜV, an independent and internationally rec- or valve position (open/closed). The position
in measurement solutions, and Bliss Americas, ognized organization that approves numerous sensor provides electronic feedback as part
a leading level and skids manufacturer, have emissions monitoring equipment, including flue of a process control system. In the isolation
teamed up to bring to the industry the most gas flowmeters, assures FCI’s customers that tube configuration, only the LVDT core lies
innovative single-chamber measuring device this meter meets its specifications, complies inside the harsh area or media. Constructed
on the market, the ACURAGE. The patented with EU air pollution directives and is suitable of metal, the core can withstand exposure
ACURAGE is the industry’s first auto calibrat- for flow data reporting per these directives. to a variety of fluids and pressures so that
ing unique radar gauge for true level reading FCI’s MT100 Series Multipoint Flow Me- the chance of LVDT core failure is virtually
and instant spot smart calibration. Made in ters combine state-of-the-art electronics nonexistent. With sensor windings in near
the USA, this ASME-approved level measur- technology with application-proven precision ambient conditions, there is a low risk of unit
ing instrument displays the level of process flow sensors in a rugged package designed failure. In an unlikely failure, the AC-operated
fluids in real time via digital display and built-in for the most demanding plant operating LVDT is accessible without disassembling a
sight glass tube. The ACURAGE features a environments. The QAL1 compliant version complicated valve housing. The LVDT housing
built-in safety ball check system to protect the has on-demand or automated instrument is easily replaced while the core stays inside
operator from accidental spillage of process self-checking with TÜV tested and certified the valve.
liquid in the unlikely event of glass breakage. test routines to analyze for sensor drift and
The ACURAGE combines built-in sight authenticate transmitter operation and to gen-
glass, highly accurate guided wave radar erate reports for documentation required by Send news and events for consideration to
technology and digital display. The device local authorities. Molly Rogers at [email protected].

NOVEMBER/DECEMBER 2021 | piprocessinstrumentation.com 7

 APPLICATION CORNER

Improper ruler
placement causes
flowmeter error
By David W. Spitzer revious articles described the sew-
Principal,
Spitzer and Boyes, LLC P age collection systems for two ad-
jacent sewage districts and how the
fourth flowmeter measured higher
David W. Spitzer is a principal
at Spitzer and Boyes, LLC,
than the actual sewage flow, which increased
which offers engineering, the first district’s bills. In addition, the more re-
focused market research, cent installation and new transmitter eliminated
writing/editing white papers, some potential sources of error.
strategic marketing consult- In particular, the previous one-point calibra-
ing, distribution consulting,
seminars and expert witness
tion technique under operating conditions could
services for manufacturing not check the flowmeter zero. As a result, the
and automation companies. flowmeter zero was not checked for years. The
Spitzer has written more than more recent installation allowed the transmitter
400 technical articles and 10 to be zeroed and spanned using the ruler on a
books about flow measure-
ment, instrumentation and
sight glass connected to the purge tubing for the
process control. He can be flowmeter primary element.
reached at 845-623-1830 or However, my findings indicated that the trans-
via spitzerandboyes.com. mitter zero was significantly out of adjustment.
How was it possible to make this determination
despite flowmeter calibration being performed and
witnessed by both parties every few months? The
answer was quite simple: read the instructions.
The differential pressure transmitter was con-
nected to a tap on the flowmeter primary ele-
ment. The instruction manual for the flowmeter
primary element indicated that the zero should
be performed by closing the valve at the tap and
removing a plug to allow liquid to drain down to
the level that would occur under zero flow con-
ditions. Performing this procedure revealed that
the ruler used to calibrate the transmitter was
positioned improperly and caused the flow mea-
surement system to measure significantly higher
than the actual flow. This resulted in significantly
higher billing for the first district, especially on
days when surcharges applied.
Next issue, read about what happened to
cause this flowmeter to be fixed.

8 P.I. PROCESS INSTRUMENTATION | NOVEMBER/DECEMBER 2021

 Which of the following orientations can be used to install a Coriolis mass flowmeter
to measure the mass flow of a condensable vapor in a vertical pipe flowing up?
A. U-tube down B. Inverted U-tube C. Horizontal (parallel to grade) D. Flag position

Coriolis mass flowmeters in vapor service must For example, a Coriolis mass flowmeter with delta-
be completely full of vapor to measure accurately. shaped tubes can accumulate liquid in the upstream
The U-tube down orientation (Answer A) could ac- (lower) portion of the tubes when mounted in a flag
cumulate liquid and should not be used for vapor position (Answer D), so the upstream and down-
applications. stream piping should be modified to mount the flow-
58407582 ©Ymgerman | Dreamstime.com

The inverted U-tube orientation (Answer B) and hori- meter with its delta-shaped tubes inverted (Answer
zontal orientation (Answer C) would entail modification B) or horizontal (Answer C).
of the upstream and downstream piping. The flag posi- Similarly, a single-path self-filling and self-draining
tion (Answer D) would typically be most practical. Coriolis mass flowmeter that forms a loop, jumps up
(sideways if mounted in flag position) and then forms

QUIZ Additional complicating factors

Not all Coriolis mass flowmeters have U-tube geom-
etry, and some of these geometries can allow liquid
another loop must be installed in the horizontal plane
(Answer C) to remove all liquid from the system be-
cause any other orientation can allow liquid to accu-
CORNER to accumulate in the flowmeter. mulate in the flowmeter.
 P R O D U C T

FOCUS
Send products for consideration in this section
to [email protected]

oxygen deficiency monitor

Process Insights launched the Alpha Omega Instruments Series 1300 as its premier
oxygen safety monitor. The Series 1300 Oxygen Deficiency Monitor is replacing the Series
1000, offering greater flexibility and improved user configurable options at a lower cost.
The Series 1300’s exclusive Advanced Digital Interface (ADI) offers the capability to expand
the Series 1300 with up to three oxygen sensors, a local sensor and/or up to two remote
sensors. The sensors in the Series 1300 are extended life electrochemical oxygen sensors
designed with a proprietary Enhanced Electrolyte System (EES). The new Series 1300 has
a measuring range of 0-30% and is housed in a resilient polycarbonate, wall-mountable
general-purpose enclosure. The Series 1300 is ideal in in environments that have closed or
restricted areas containing stored or piped inert gases, such as labs and processing plants.

www.aoi-corp.com

clamp-on ultrasonic flowmeter

VorTek Instruments recently released the SonoPro U44
Portable clamp-on ultrasonic flowmeter. The SonoPro
U44 Portable offers high-accuracy transit-time ultrasonic
ultrasonic flowmeter technology to deliver accurate and economical flow metering
in a portable design. The innovative design incorporates
AW-Lake Company introduces a Water Inline (WIN) Ultrasonic matched precision transducers and signal processing
Flow Meter for highly accurate and reliable flow measurement circuitry to accurately measure the flow of most liquids over
of cooling water, condensing water and water/glycol solutions. a wide range of velocities. Clamp-on transducers create
Designed for process cooling applications including industrial no wear, zero pressure loss and do not require process
cooling circuits, the WIN Ultrasonic Flow Meter has no moving interruptions for installation. With the addition of external
parts for long-term reliability and low maintenance costs. By temperature inputs, the SonoPro U44 Portable can provide
incorporating two wetted ultrasonic transducers that face a reliable (BTU) thermal energy measurement.
each other directly in the flow tube, the meter reduces wear
associated with moving parts and maximizes signal strength. www.vortekinst.com
The meter offers high accuracy (+1.0% of reading over 25:1
turndown, 100:1 total turndown) over a wide flow range
with minimal pressure drop. An innovative flow tube design
simplifies installation in limited straight runs and ensures no
obstruction in the flow path. Holding an IP67 (NEMA 6) rating,
it operates safely when temporarily submerged in water.

www.aw-lake.com

10 P.I. PROCESS INSTRUMENTATION | NOVEMBER/DECEMBER 2021

 NEW PRODUCTS

panel meter
Red Lion’s graphical panel meter, PM-50, expands the
company's existing award-winning panel meter portfolio.
The PM-50 is available as a 3.5-inch or 4.3-inch graphical
touchscreen display. Using simple “swipe” technology,
users can easily switch between relevant screens and
receive comprehensive operational data for monitoring
liquid level reader equipment and production. Visual alerts notify the user that
immediate action is necessary, either on the unit itself or
Q.E.D. Environmental Systems Inc. (QED)’s Precision via PM-50 app, available on Google Play or Apple Store.
Level Reader (PLR), is an accurate, safe and efficient The PM-50 offers built-in Wi-Fi connectivity for users to
method for determining leachate and/or condensate levels remotely access critical workflow and process data from
in gas wells. With QED’s new PLR device, liquid levels are the confines of the plant floor to create a smarter plant
detected within seconds and are recorded with a time, date floor. Wired connectivity is also an option via Ethernet and
and location stamp with no need to interrupt the vacuum in Modbus. The PM-50 can replace a meter with a 1/8 or 1/16
the well. Using a permanently installed weight and tube, the DIN panel cut out.
PLR engages a micro-compressor and differential sensors
to determine a water level reading that is never affected by www.redlion.net
foam and will not cross-contaminate from well to well. With
no need for a water tape or well seal removal, level readings
take a fraction of the time and effort, with no exposure of
technicians to dangerous gases or liquids in the process.

www.qedenv.com

liquid level controllers

AutomationDirect added new ProSense CLC series conductive liquid level controllers to its
line of level sensors and controllers. The CLC series level controllers detect and control levels
of conductive liquids (tap water, seawater, sewage, chemical solutions, coffee, milk, etc.)
in dual-probe pump-up (fill) and/or pump-down (drain) applications. These controllers
compare the measured resistance value between the high/low probes and a common (either
the tank wall or a third probe) with the set point controlled by the onboard potentiometer.
A wide adjustable sensitivity range is included to meet a large variety of liquid types.
These level controllers pulse the probes with a DC voltage to prevent potential electroplating
issues and the output relay can control pumps, solenoids or valves to automatically lower,
raise or maintain the liquid level in the tank.

www.automationdirect.com

NOVEMBER/DECEMBER 2021 | piprocessinstrumentation.com 11

 COVER STORY: MULTIVARIABLE MEASUREMENT

Utilizing
or a multivariable vortex flowmeter,
as they are the most common types
of multivariable instrumentation. But
taking the word at its literal mean-

MULTIVARIABLE
ing, a proper definition would be the
measurement of more than one inde-
pendent process variable in a single
stand-alone instrument. The list of

MEASUREMENT
instrumentation that fits this defini-
tion has been and will likely continue
to grow.
So, what is the purpose of having
multiple sensors in a single instrument?
Multivariable measurement fits into
Reduce installation and maintenance costs two broad use-case categories:
• Multiple measurements
while gaining process insights. By Ryan Bennett, VorTek Instruments
| • Compensative measurements

Multiple measurements
ultivariable measurement has measurement becoming the norm rather This use-case category consists of mea-

M been gaining a much wider

acceptance over the last de-
cade as end users come to un-
than the exception.

What is multivariable
surements that are useful as individual
stand-alone measurements, but add-
ing them to a single instrument low-
derstand the value of capturing additional measurement? ers associated installation and main-
process variables. As progress continues Upon hearing this term, many think of tenance costs. An example would be a
toward the Fourth Industrial Revolution, a multivariable pressure transmitter multivariable vortex flowmeter, where
the trend in process facilities will continue
to be adding more measurement points to
collect more relevant data. More relevant
data paints a more complete picture of the
individual processes and how they interact
holistically. For instrument manufactur-
ers, this trend will mean adding more vari-
ables to single variable instrumentation.
Ultimately, this will lead to multivariable

 Figure 1: Multivariable
insertion vortex flowmeter
on a steam line.
Photo by Kay Gibbs
Photography.
All images courtesy of
VorTek Instruments
  Figure 2: Velocity, temperature and pressure
sensors clustered behind the bluff body of a
multivariable vortex flowmeter.

produce a variety of process variables,

covering the more conventional pro-
cess variables such as flow, pressure,
temperature and level, as well as less
conventional process variables such
as density, viscosity and liquid conduc-
tivity. Many of these less conventional
process variables are used in interme-
diate calculations, so the operator may
not even be aware of their availability.
But, depending on the process, they
may also prove valuable as stand-alone
process variables.
The first multivariable instruments
were multivariable pressure transmit-
ters developed in the early 1990s. In
addition to being the first, these trans-
mitters are perhaps the most versatile
type of multivariable instrumentation.
Adding temperature and differential
the operator uses the temperature and intermediate calculation of fluid den- pressure sensors gives this technology
pressure measurements as stand- sity, which is then used to calculate the the ability to calculate fluid density and
alone measurements. mass flow rate of a compressible fluid. mass rate in flow metering applications.
Without compensating for the fluid This same ability to calculate fluid den-
Compensative density, an accurate mass flow rate cal- sity proves valuable in tank level mea-
measurements culation would be impossible. surement applications as well.
Compensative mea- Vortex flowmeters are another com-
surements improve Multivariable instrument types monly used multivariable instrument.
the performance of Modern multivariable instruments can Similar to the multivariable pressure
existing measure-
ments or allow for
the calculation of ad-
ditional measurements that
would otherwise be unavailable.
An example of improving perfor-
mance would be using a temperature
sensor to correct for temperature fluc-
tuations that can affect the accuracy of
a pressure transducer using strain gauge
technology. The operator is not inter-
ested in the temperature measurement
itself but benefits from the improved ac-
curacy of the pressure measurement.
An example of calculating additional
measurements would be adding tem-
perature and static pressure sensors
to a differential pressure transmitter.
These additional sensors allow for the  Figure 3: A vortex flowmeter can provide a variety of process variable outputs.

NOVEMBER/DECEMBER 2021 | piprocessinstrumentation.com 13

 This method is a popular choice, but it
“Having these sensors in a single instrument reduces the certainly has its downsides. If you add up
number of pipe penetrations, the amount of wiring and the number of multivariable instruments
and the number of variables on those in-
the number of devices.”
struments, it becomes apparent rather
quickly that this method could require
an extreme amount of wiring — as many
wires as variables. Excessive wiring also
means taking up valuable I/O space in
the control room.
HART (Highway Addressable Remote
Transducer) protocol is an open stan-
dard used to send and receive digital in-
formation using analog wiring between
devices and control systems. HART
signals share the pair of wires used by
analog signals. In effect, additional data
is transferred without additional wiring.
This fact alone makes HART an excel-
lent choice for capturing supplemental
process variables. HART has also been
adopted widely across process facilities.
So, it is a familiar technology, and many
existing I/O cards can capture this
 Figure 4: Single-variable instrumentation versus a multivariable vortex flowmeter.
HART data. However, HART does have
limitations. The speed of HART com-
munications is relatively low. Therefore,
transmitter, adding temperature and provide valuable insight into a process. some operators prefer only to use HART
pressure measurements gives these However, these variables are not of any data for monitoring purposes.
flowmeters the ability to calculate fluid value unless they make it back to the Perhaps the best solution for captur-
density and mass flow rate. Combining control room, which begs the question, ing this additional data is digital fieldbus
the ability to measure mass flow rate what is the best method to capture all protocols. Many different fieldbus pro-
and the vortex flowmeter’s inherently of these additional data points? tocols are available; some are open, and
rugged design make it one of the best In this age of the Internet of Things some are proprietary to a specific ven-
options for mass flow rate metering of (IoT), there are abundant methods dor. But, they all allow for a large amount
saturated steam. to capture this data. But the method of data transfer at a rapid rate. Also, all of
Coriolis flowmeters measure mass chosen will likely hinge on two factors the data rides on the same physical layer.
flow directly as their primary measure- — the facility’s overarching communi- So, multiple process variables communi-
ment. As such, most people view Corio- cation strategy and whether the addi- cate over the same wiring, which is a sig-
lis flowmeters solely as high-accuracy tional data is for monitoring or control. nificant advantage over analog signals.
mass flow measurement devices. But, Monitoring is the process of collecting A newer option is wireless data trans-
many Coriolis flowmeters can also process data without using it as part of mission using WirelessHART. Data is sent
provide fluid temperature, density and an active control loop. Process variables wirelessly from the instrument to a re-
viscosity measurements. Similarly, elec- used for monitoring purposes gener- ceiver or gateway. From the gateway, this
tromagnetic flowmeters are generally ally have less stringent requirements data can be hard-wired to the control sys-
thought of as high-accuracy volumetric for availability and speed. More critical tem using a digital fieldbus protocol. This
flow measurement devices, but many process variables used in active control option is a particularly great solution for
can also provide liquid conductivity and loops must meet minimum require- retrofitting existing multivariable instru-
temperature measurements. ments for availability and speed. ments that speak HART. A WirelessHART
Analog signals (4-20 mA) still dominate adapter can be added to the existing in-
Capturing the supplemental data most process facilities. Many multivari- strument instead of replacing older I/O
The additional process variables that able instruments offer dedicated analog cards that do not communicate HART. In
multivariable instruments supply can outputs for each variable measured. this way, WirelessHART communication

14 P.I. PROCESS INSTRUMENTATION | NOVEMBER/DECEMBER 2021

does not interfere with the instrument’s
wired connection to the control system.

Applications best suited for

multivariable measurement
While most process facilities will have
ample opportunities to utilize multi-
variable measurements, there are un-
doubtedly specific applications where
these measurements shine.
Compressible fluids such as gases
and steam quite often experience
changes in their density. Volumetric
flowmeters cannot account for these
changes and will produce an inaccurate
flow measurement.
Therefore, density compensated mass
flow metering is a better method of flow
metering for compressible fluids. Tem-
perature and pressure measurements
are used to calculate fluid density. This
fluid density is then used in combination
with volumetric flow rate to calculate a
 Figure 5: Thermal energy metering with a clamp-on ultrasonic meter.
mass flow rate. Both multivariable vor-
tex and differential pressure flowmeters
utilize this method of mass flow me-
tering. Having these sensors in a single • Lower upfront cost versus buying Conclusion
instrument reduces the number of pipe multiple single-variable instruments. Multivariable measurement will con-
penetrations, the amount of wiring and • Fewer number of pipe penetra- tinue to grow in use as the benefits out-
the number of devices. tions and potential leak points weigh the drawbacks for an increasing
Thermal energy metering, or BTU me- versus multiple single-variable number of applications. The additional
tering, is the measurement of energy in instruments. process variables that multivariable
hydronic or steam-based heating and • Fewer number of electrical connec- instruments supply can provide valu-
cooling systems. Thermal energy me- tions and less cabling versus multi- able insight into a process. However,
tering requires multiple measurements ple single-variable instruments. capturing this additional data will
in the form of volumetric flow rate and • Fewer number of overall devices in challenge facilities to create new com-
fluid temperature. Calculations are per- the field. munications strategies or adjust their
formed with these measurements to pro- • Can correct for potential sources of existing strategy accordingly. Facilities
duce a thermal energy measurement. error, such as changes in fluid density. that successfully adapt will undoubt-
• Can provide compensative mea- edly reap the many rewards offered by
Advantages and disadvantages surements, such as mass flow rate. multivariable measurement.
of multivariable measurement • More process variables can lead to
Like any technology, multivariable in- more insight into a process. Ryan Bennett is a product
struments have their own merits and marketing manager for VorTek
limitations. Ultimately, the intended Key disadvantages of multivariable Instruments in Longmont,
application will significantly influence measurement include: Colorado. He holds a B.S. in
whether the technology is advantageous • Higher upfront cost versus a compa- industrial distribution from the University of
over single-variable measurement. rable single-variable instrument. Alabama at Birmingham. Bennett has had
Key advantages of multivariable mea- • Additional data is of no use unless a strong focus on flow metering throughout
surement include: there is a viable way of bringing it his career. He has worked in various roles at
• Lower installation and maintenance back to the control system. VorTek Instruments, with a current focus on
costs versus multiple single-variable • Embedded sensors could be chal- new product development and marketing. He
instruments. lenging to replace if there is a failure. can be reached at [email protected].

NOVEMBER/DECEMBER 2021 | piprocessinstrumentation.com 15

 OIL & GAS

Meeting challenges for deep-sea gas production

Subsea flowmeter solutions can help mitigate risks before they become severe.
By Svein Eirik Monge, Emerson

eveloping a subsea gas field is risks. With the onset of unexpected wa- A hydrate plug, for example, can form

D not a simple process. In fact,

it is long, costly and complex.
Even more so than a topside
ter in a well, many operators react with
alarm. Unanticipated water production
can significantly reduce the value of the
in as little as 20 minutes. Understanding
flow conditions for forming hydrates,
based on the data received from the
well, a subsea well provides a complex hydrocarbon asset, accelerate damage subsea flowmeter, means immediate
set of additional challenges. Great water to equipment and increase the cost of action can be taken to dissolve the plug
depths are an obvious challenge — with handling and disposal. before it causes disruptions to the flow.
rugged seabeds, high production pressure In fact, unchecked water can lead to Additionally, subsea tieback devel-
and temperatures all adding to the engi- scaling in the production system and cat- opments that enable long-distance
neering challenges to design a suitable so- astrophic water breakthrough with water tieback opportunities for remote and
lution for subsea production systems. coning and impairment of the well, caus- marginal fields have only exacerbated
Since the first subsea well was pio- ing a significant reduction of well produc- the danger. This can lead to delays be-
neered off the coast of California in 1961, tion. The worst-case scenario in these fore the onset of formation water is de-
oil and gas processors have designed and situations is the subsea well being shut tected and measured topside. In such
100664893 ©Pichit Boonhuad | Dreamstime.com

developed different ways to effectively down or having a shorter life span. cases, it might be too late to react and
deal with the unique issues that need to With water and solids entering the flow save the well. The key drivers for the
be considered for a subsea field. line, the subsea production system may be operator are to increase recoverable
Operators are looking for sophisti- subject to long-term risks, such as corro- assets and optimize production, guar-
cated subsea technologies that can provide sion/erosion, and short-term risks, such as antee flow assurance, and ensure that
real-time information on flow perfor- hydrates. Formation water properties vary operational decisions can be made in
mance, protect well integrity, ensure from one reservoir to another, often within a timely manner with the most up-to-
more effective production operations the reservoir as well. Detecting formation date information available.
and pre-empt production threats. water breakthrough is crucial for well and The oil and gas industry is increasingly
In a gas well, where water, other flu- reservoir management, and by installing turning to natural gas resources as tech-
ids and solids are produced, it is impor- dedicated subsea flowmeters, the opera- nological advances and digitalization
tant to accurately measure and control tors can take action to mitigate these risks unlock new reservoirs previously con-
these so that operators can mitigate before they become severe. sidered too difficult or costly to tackle.

16 P.I. PROCESS INSTRUMENTATION | NOVEMBER/DECEMBER 2021

Natural gas is also a lower carbon emis- scale and corrosion inhibitors accordingly environmental risks. The operator may
sion alternative to other hydrocarbon — without flooding the well as was pre- choose low alloy steel pipes (saving
fuels, playing a key role in lowering CO2 viously sometimes the case with mono- CAPEX), and, with full control over the
emissions and meeting important envi- ethylene glycol (MEG). Small pockets of fluids produced, they can take the re-
ronmental impact goals. As the industry formation water seeping into the wellbore quired steps to avoid the impact to the
moves in this direction, subsea flowmeter can therefore be detected instantaneously pipe by injecting just the needed amount
solutions need to provide highly sensi- with the salinity system, providing quan- of chemicals. By not over-injecting
tive and accurate real-time flow mea- titative and qualitative real-time measure- chemicals, OPEX is also reduced.
surements for wet gas streams. ments in a wide variety of field conditions.
Subsea flowmeters are used for res- Figure 1 gives an overview of the types After the installation
ervoir management, enabling the op- of available measurement options incor- As important as it is to engineer the
erators to adjust the well to an optimum porated in a subsea wet gas meter. correct solutions for a subsea well, so
level and maximize hydrocarbon pro- too is the aftercare of an installation.
duction while minimizing water produc- Knowing a gas production company
tion. This is important to enable a high has access to skilled support from the
recovery factor in the field. Reservoir manufacturer becomes a highly prized
management today is about creating a benefit — should support be needed.
sustainable production strategy; one Having skilled technicians available
that negates production threats, at strategic locations around the
provides insight into operations world near big oil and gas produc-
and maximizes production. tion fields builds peace of mind
and ensures that unexpected
Types of measurements shutdowns are resolved quickly.
in multiphase flow Subsea gas production sites are
To measure multiphase flow, a found worldwide, supplying both
flowmeter needs to utilize differ- commercial and residential cus-
ent measurement techniques to be tomers with the fuel they need to
able to measure the different fluids run their daily businesses and lives.
within a flow line. For gas fields, water Placing support and repair facilities at
is often a concern due to the aforemen- a reasonable distance to those larger gas
tioned risks, and therefore, there are production areas benefits both the pro-
dedicated subsea flowmeters for these  Figure 1: Subsea wet gas meter add-on ducers and the equipment manufacturer.
applications to ensure the best perfor- modules to resolve field-specific challenges. Today, the world still relies on hydro-
mance is available to the operators. Courtesy of Emerson carbons. Ensuring those reach customers
Wet gas flow measurement is signifi- without interruption requires both care-
cantly more complicated than measuring ful planning and the right equipment.
the single-phase flow of dry gas. To solve The subsea wet gas meter is engi- Significant innovations in technology
these challenges, a leading manufacturer neered specifically to meet the chal- and software for deep-sea production
of subsea wet gas flowmeters has designed lenges described here. It consists of an ensure that customers are supplied with
dedicated subsea wet gas meters to accu- all-in-one device, with additional add- fuel and producers can maximize well ef-
rately measure hydrocarbons and water on modules for field-specific challenges. ficiency and production with lower risks.
using electromagnetic responses, pressure, The subsea wet gas meter has improved
temperature and velocity sensors. Wet gas Long-term benefits production across the globe.
meters provide real-time, accurate subsea The immediate dangers are well known
measurements of hydrocarbon flow rates to a subsea gas producer; however, the Svein Eirik Monge is a com-
and water production — crucial decision- long-term risks must also be consid- mercial manager for Emerson’s
making information for the operator. ered. Corrosion is especially dangerous Roxar flow measurement prod-
The accurate measurement of water when the majority of pipes are in deep ucts and has been with the
salinity has also become increasingly im- waters. Having a subsea wet gas meter company for over 15 years. Monge’s previous
portant. Salinity measurement tells the that reports on the corrosive nature of roles with Emerson’s Roxar products include
reservoir engineer whether formation the fluids flowing through the pipes production technician, service engineer, ser-
water is entering the flow and helps the can allow for greater vigilance on the vice project manager, and product manager for
process engineer adjust injection rates of part of the operator, thereby reducing the Roxar Subsea Wetgas Meter.

NOVEMBER/DECEMBER 2021 | piprocessinstrumentation.com 17

 CALIBRATION

General principles of flowmeter calibration

For flowmeters, there are considerations such as accuracy, repeatability, methods of
calibration and calibration fluid to ensure a correct and transferable calibration is performed.
By Harry Clark, TÜV SÜD National Engineering Laboratory

alibration is not an abso- demonstrate traceability to higher level For flow measurement applications,

C lute operation, but rather

a comparison. A device’s
performance is evaluated
measurements and ultimately to na-
tional and international standards. This
is outlined in the various standards and
the confidence in the result lying within
the uncertainty is normally quoted
with a “coverage factor” of k=2, which
against a reference standard, which guidelines, such as ISO 17025. is approximately 95% confidence level
can take various forms depending on To correctly express the performance — meaning we are 95% confident that
the quantity that is being measured. In accuracy of any standard or measure- the true value lies within the stated
flow measurement terms, a standard is ment system, the uncertainty must be uncertainty range associated with the
a system that comprises of a measure evaluated and quantified. The uncer- measured value. All calibration results
of fluid quantity over a time period and tainty of the measurement is deter- should have a stated uncertainty and
subsidiary measurements to determine mined by analyzing and summating all “coverage factor” on the calibration re-
the fluid conditions, properties and in- the individual sources of uncertainty port or certificate.
fluencing factors. All the measurements that pertain to the system. Uncertainty Accuracy is not the only measure of
in the system are part of the standard, can then be expressed as the measured performance that is evaluated during
not just the measured quantity. value alongside the absolute or relative a calibration. Another important per-
To have confidence in the reference uncertainty, where there is a given level formance indicator is the repeatability
standard measurement, all contribut- of confidence that the true value lies of the device — how closely the group
ing measurements in the system must within the uncertainty range. of measurements lie. A device with

18 P.I. PROCESS INSTRUMENTATION | NOVEMBER/DECEMBER 2021

 fill the vessel is known, the flow rate fluid flows through the prover, a timer is
can be calculated. The “standing start started at detector one and stopped at
and stop” calibrations of flowmeters detector two, and an accurate volume
are the simplest method available and flow rate is determined. Provers can use
can be used for both high and low accu- different fluids and operate at different
racy calibrations. With this method, the temperatures and pressures, and if the
fluid flow is started and stopped using appropriate corrections are applied,
a valve, and the timing begins as soon the results will be accurate. Provers of-
as the flow starts. The timing then ends fer similar measurement uncertainty
when the flow is stopped. to laboratory calibrations and allow for
The “flying start and finish” method live fluids to be used.
is sometimes called the diverter meth- Verification methods can be used
od, where the flow through the meter to provide confidence in a measure-
is not stopped but continues uninter- ment but is not technically a calibration
rupted and is physically diverted be- since the check meter will normally be
tween a return path to the liquid sup- of comparable or poorer accuracy. It
ply tank and the collection container. is often used where meters cannot be
A switch on the diverter mechanism removed from service, but an indica-
 One important performance indicator is the
repeatability of a device. starts and stops a timer and a pulse tion of the meter’s performance must
totalizer. An advantage of this method be acquired. Typically, these verifica-
All images courtesy of TÜV SÜD
National Engineering Laboratory over “standing start and stop” is that tion devices fall into the categories of
the line conditions can be better con- non-invasive (or clamp-on) technology
trolled. Since the flow is never physi- or insertion methods. These methods
good repeatability will typically have a cally stopped, temperature control and tend to be portable (although insertion
lower measurement uncertainty associ- stability are generally better. methods require some infrastructure to
ated with it. Even if there is an error or “Bucket and stopwatch” systems are be in place), can be installed when the
bias in the device’s measurement from not the only option for laboratory cali- line is operating and provide a rough in-
standard, this can be easily corrected. If brations; dynamic options are available dication of the flow rate (1% to 5%).
the repeatability of the device is poor, it where the flow is continuous through Laboratory gas calibrations tend to use
is very difficult to improve the accuracy. the device under test as well as the a purpose-built closed-loop system, which
Reproducibility is also important, as it standard. This is normally referred to as relies on a primary standard, such as a
is an indication of the device’s ability to the “master meter” method. The com- volumetric prover or gravimetric system.
reproduce the same performance when parison is made between the device un- This system is then used to calibrate the
the same flow rate and conditions are der test and the master meter, which is “working” or “secondary” standard, nor-
repeated on a different occasion. traceable to national and international mally comprising of a reference flowme-
standards. Master meter systems are ter or sonic nozzle assembly. The second-
Flow calibration methods generally less accurate than other labo- ary standard is then compared with the
There are many different methods of ratory calibration methods. However, test meter to evaluate its performance.
flowmeter calibration, and these will they have an advantage of being much
vary in their techniques, methods and more compact and can easily be trans-
implementation. However, they can be ferred between locations.
placed under three categories: laboratory Outside of the laboratory setting,
calibration methods, master meters where calibration or verification is re-
and verification methods. quired in the field, the master meter
Laboratory calibration standards method can also be used. Normally,
can be considered as being “bucket these are other flowmeters, but for high-
and stopwatch” systems, whereby the accuracy applications, a prover loop
bucket is a vessel that is weighed or has is used. This is incredibly useful in the
a known volume, and the stopwatch field as it can allow the meter to be cali-
aspect is the time taken to fill the ves- brated in-situ, provided there is a dedi-
sel. The quantity of fluid collected is cated stream. A prover loop consists of
measured and compared with the test a dedicated flow stream with a known Accuracy is not the only measure evaluated during
meter reading, and since the time to volume between detectors. As the a calibration.

NOVEMBER/DECEMBER 2021 | piprocessinstrumentation.com 19

The importance of calibration Since flow profile can have an influ- profiles and require careful consideration
fluid and conditions ence on the performance of a flowmeter, when designing the installation.
Calibration conditions are an important as- consideration must be given to the instal- In an ideal world, it would be best to
pect in the flowmeter calibration process. lation. Flowmeters are designed to oper- calibrate the test meter in-situ, using the
All flowmeters are influenced to some ex- ate in “fully developed flow,” where there fluid it will measure in use. Practically
tent by the fluid properties and flow profile is minimal distortion of the symmetrical speaking, this usually is not possible, and
presented at the device under test. As the distribution of velocity across the section of so it is important to try and replicate, as
fluid passes through the pipe, the velocity a pipe. Process equipment, pipe geometry close as practically possible, the condi-
profile across the pipe is influenced by the changes, bends and valves introduce asym- tions that the flowmeter will be subjected
internal diameter, roughness and Reynolds metrical and possibly swirling flow. The re- to in service. This can include using the
number. Reynolds number is a function sulting disturbances in the flow profile are same pipework configuration and a fluid
of the physical properties of the fluid, the referred to as installation effects and can with similar properties. It is seldom pos-
pipe geometry and flow rate of the fluid. cause errors in the measured flow through sible to perfectly match the service con-
Since Reynolds number can have a large the meter. The magnitude of these effects ditions and installation, but any error
influence on the performance of the flow- will depend on the type of disturbance and due to this would be small and accounted
meter, it is important to ensure that the the type of flowmeter that is being used. for in the uncertainty of the device.
operational range of Reynolds number is Coriolis flowmeters are typically consid-
covered during the calibration. For exam- ered to be immune to installation effects How often should a
ple, calibrating a flowmeter in water and and are a good choice where the installa- flowmeter be calibrated?
using it for a hydrocarbon with a greater tion may not be ideal. Traditional metering The interval for calibration will depend on
viscosity, will likely result in a significant technologies such as turbine and differen- the type of measurement being made and
measurement bias introduced through tial pressure meters can be highly influ- why. Often, industry standards or a third-
an inappropriate calibration factor. enced by swirling and asymmetric velocity party (regulator or trading partner) dictate

Flow Measurement for All

Your Process Cooling Needs
From Chillers and Coolant Loops to Water Heaters and Heat Exchangers, monitoring
industrial coolant flow is important to protect your equipment, save energy, and

FLOW increase efficiency. Whether you have a massive chiller unit in your plant or a cooling
circuit inside a piece of expensive equipment – there’s a flow meter to meet your needs.

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Ultrasonic * Turbine
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aw-lake.com | [email protected] | 414.574.4300

20 2112PI_AWLake.indd
P.I. PROCESS INSTRUMENTATION
1 | NOVEMBER/DECEMBER 2021 11/10/21 3:45 PM
 calibrated. If these conditions are changed
“Whatever the frequency, it is good practice to keep calibration in service, the calibration may not apply
graphs and control charts of the meter performance, as this will and it may be time to recalibrate the meter.
assist in interval selection and highlight changes in performance.” Calibration is an essential part of suc-
cessful process operations, and without
it, there would be little confidence in
the frequency of calibration where high ac- providing a realistic and evidence-based measured values. For flowmeters, there
curacy measurement is required. This can interval. Condition-based intervals are de- are many more considerations the end
include custody and fiscal transfer, where termined using meter diagnostics to pro- user must be aware of to ensure a cor-
the interval is chosen to minimize the risk vide an indication of the meter’s health. In rect and transferable calibration is per-
of an incorrect meter reading, which can this case, the meter tells the user when a formed on their equipment. Care must
result in a mismeasurement scenario. calibration is required. be taken in deciding when, where and
For many other applications, how- Whatever the frequency, it is always how to complete the calibration — using
ever, it is the user who must define the good practice to keep calibration graphs the information provided here as guid-
calibration interval and type of calibra- and control charts of the meter perfor- ance for end users.
tion required. The frequency of calibration mance, as this will assist in interval se-
can be selected using three different ap- lection and highlight changes in perfor- Harry Clark is a facility lead at
proaches: calendar-based, risk-based and mance that may indicate degradation of TÜV SÜD National Engineering
condition-based intervals. The calendar- meter performance. Laboratory, a provider of techni-
based approach relies on a selected time Whatever methods are chosen, it is cal consultancy, research, testing
period between calibrations. Risk-based important to consider that the calibra- and program management services. Part of the
intervals use previous calibration data tion applies to that meter only, operating TÜV SÜD Group, it is a global center of excellence
to estimate drift in the measurement, under the conditions with which it was for flow measurement and fluid flow systems.

NOVEMBER/DECEMBER 2021 | piprocessinstrumentation.com 21

 Q&A: LEVEL MEASUREMENT

All images courtesy of Endress+Hauser

Radar versus ultrasonic sensors:
Fit-for-purpose technology

Q+A
Comparing the advantages and disadvantages can help
you find the best solution for reliable level measurement.
adar technology is increas-
Q: What is ultrasonic level

R ingly viewed as the best

method of level measure-
ment, but this is not neces- A:
measurement?
Ultrasonic level sensors use the
time of flight (ToF) principle to
sarily true for every application. Radar measure level. The ultrasonic transducer
sensors have certainly made great ad- generates a mechanical sound pulse,
vancements in performance, accuracy which is directed through the air to the
and even cost, but they are not a one- process. When this pulse encounters
size-fits-all solution and should not be the process surface, it reflects back to
treated like one. the transducer. The transmitter is basi-
Although radar is versatile, there cally a high-tech timer, measuring the
with are some applications where ultra- time it takes the pulse to travel to the
SCOTT PETERSON sonic level technology is a better fit. process and back. This time is directly
Endress+Hauser USA Approaching level measurement with proportional to the distance from the
a fit-for-purpose mindset instead of gauge to the process surface.
a blanket approach is important for
safety, performance and overall prod-
uct quality. Q: What are the differences
between ultrasonic and radar
Endress+Hauser’s level expert, Scott level measurement sensors?
Peterson, discusses the differences and
benefits of ultrasonic and radar tech-
nologies and which applications ultra-
A: Radar level measurement oper-
ates based on the same ToF prin-
ciple as ultrasonic; however, radar uses
sonic should be considered. high frequency microwaves emitted

22 P.I. PROCESS INSTRUMENTATION | NOVEMBER/DECEMBER 2021

from an antenna. Rather than reflecting
based on a change in density as sound
waves do, microwaves reflect based on
a change in impedance caused by the
change from a low dielectric medium
(air) and a higher dielectric constant of
the process medium. Since microwaves
are electromagnetic and do not require
air as a transmission medium, radar is
well-suited for use in a vacuum or when
other gases are present in the empty
space. Radar is a safe solution even un-
der extreme process conditions includ-
ing pressure, temperature and vapors.

Q: What are the benefits and

advantages of ultrasonic
 Figure 1: Ultrasonic measurement
Time-of-Flight FMU42.
level measurement?  Figure 2: Prosonic FDU91 PP.

A: The ultrasonic method is a proven

and cost-effective solution for level
measurement in liquids and bulk solids.
It is characterized by easy planning and
assembly, fast and safe commissioning,
challenges caused by dust buildup or con-
densation on the transducer’s faceplate; Q: What ultrasonic level
measurement devices
a long service life and reduced mainte- however, an ultrasonic sensor equipped does Endress+Hauser offer?
nance costs. Since ultrasonic does not
rely on dielectric constant for reflection,
with automatic self-cleaning, such as the
Endress+Hauser Prosonic FDU91, elimi-
nates failures caused by dust buildup.
A: Endress+Hauser offers a broad
range of devices for ultrasonic level
it is well suited in use where the process measurement. The Endress+Hauser
media has low (less than 1.5) dielectric Prosonic product line features 12 ul-
constant, with the exception of hydro-
carbons. It is also well suited for open Q: What challenges can ultrasonic
level measurement help overcome?
trasonic, ToF sensors and two power-
ful transmitters. All are unaffected by
channel flow measurement and in use
with weirs or flumes. A: Ultrasonic sensors can help over-
come the challenges end users
might experience in tight spaces. They
dielectric constant, density and humid-
ity. They are also unaffected by buildup
of dust or condensation. The Prosonic

Q: What are some common

applications where
are ideal for installation in tight places
due to the relatively small size of the sen-
FMU90 ultrasonic transmitter coupled
with a FDU9X transducer is an excellent
ultrasonic sensors are used sor and the ability to mount a sensor di- choice for many of these applications.
and should be considered? rectly to a ceiling. An ultrasonic sensor The FMU90 offers additional features

A: The main limiting factor for radar

is the dielectric constant. Materi-
als with low dielectric constants may
can also be helpful in cases of flooding;
when used with a flooding protection
tube, the sensor can ensure a high mea-
like totalization, data logging, differen-
tial measurement, pump control and
open channel flow tables. The FMU90 is
not provide enough change in imped- surement is indicated even if it is under also available in a two-channel model to
ance to cause a reflection. This re- water. In outdoor installations, where reduce overall hardware costs.
sults in the microwave energy passing temperatures can drop below freezing,
through it and reflecting off the vessel ultrasonic sensors with an integral heater Scott Peterson is the national product manager
bottom. Some materials with dielectric can prevent ice formation on the device. at Endress+Hauser USA for level. He is re-
constants too low for free space radar This would ensure reliable measurement sponsible for the strategic direction of the level
are dry sawdust, wood chips, white year-round. Icing can cause issues with business unit including life-cycle management,
cement and many plastic pellets. For radar, as the ice has a high dielectric technology and application identification, as well
these applications, ultrasonic transmit- constant, which may attenuate the radar as marketing and business development for the
ters can provide a measurement where signal at or near the source. If this occurs, level products. Peterson has a Bachelor of Sci-
the radar transmitter would not. there will not be sufficient radar signal ence in electrical engineering, and he has spent
Some users moved away from ul- reaching the product surface to give a more than 32 years in process instrumentation
trasonic sensors because of previous level measurement. and control with industry-leading companies.

NOVEMBER/DECEMBER 2021 | piprocessinstrumentation.com 23

 INSTRUMENTATION

Maximizing return on investment P

rocess analyzers can help
plants achieve accurate
measurements in an indus-

from your process analyzer trial sampling system, help-

ing to ensure that the desired amount
of on-spec product is being produced
Process analyzers are a significant monetary safely and at the lowest cost. Analyzers
are, however, a more significant invest-
investment, but they have major potential to ment than other measuring devices. As
such, procurement managers at some
improve production outputs and reduce downtime. organizations may require justification
for this type of purchase. Being able to
demonstrate the clear value and return
By Karim Mahraz, Swagelok
on investment for using an analyzer for
quality control can be helpful.
By helping to improve production
outputs and reduce system downtime,

24 P.I. PROCESS INSTRUMENTATION | NOVEMBER/DECEMBER 2021

 Digital
Pressure
Gauge
MAN-SC/LC

 Figure 2: This chart illustrates quality giveaway,

which can occur when quality variations are high
for fear of making an off-spec product.
©2013 Industrial Sampling Systems provided
by Swagelok.

Multiple analyzers, operating either

manually or automatically, will help
your plant achieve this savings goal • First Gauge Worldwide with IO-Link
• MAN-SC - Battery Powered
across three key categories: process
• MAN-LC - 24 VDC Power and IO-Link
control, quality assurance and plant • Capacitive Touchpads
safety. This article will explore each of • Peak Memory
these topics and how they can influence • Variety of Outputs Available
your return on investment analysis. • Up to Two Output Relays
• Stainless Steel Process Connection
• Numerous Diaphragm Seals Possible
Process control • Ceramic or Metal Sensor
Process analyzers allow for the fine- • 12 Selectable Measuring Units
tuning of fluid process streams, helping
organizations ensure the production of
high-quality, profitable products.
 Figure 1: Analyzers can help plants improve They can be helpful no matter the
safety, process control and quality assurance. market conditions, which often influ-
©2021 Swagelok ence an organization’s process control
strategy. Under softer demand condi-
process analyzers can indeed demon- tions, and with a plant running at below
strate sizable returns on investment if maximum capacity, process control is
they are set up and integrated properly typically focused on minimizing the
into the system design. To calculate a cost of production — including energy
return figure, operators can gather the consumption and waste — while main-
upfront cost of purchasing an analyzer taining high quality. When demand is The MAN-SC/LC features a housing
and the ongoing cost of ownership to high, analyzers can help operators max- that can rotate 360° and a display that
rotates in 90° increments. Shown here
understand anticipated expenses. Then, imize throughput to sell as much prod- with optional rubber protection sleeve.
they can note the expected benefits and uct as the plant can produce. But under
resulting savings the analyzer enables. It any market condition, customers will
is possible such an analysis can demon- expect a product that meets their speci- www.koboldusa.com
strate savings in the magnitude of up to fications and quality expectations. A 1.800.998.1020
thousands of dollars per day. poor product can dramatically impact

NOVEMBER/DECEMBER 2021 | piprocessinstrumentation.com

2112PI_KoboldInstruments.indd 1
25
11/12/21 4:43 PM
 priority. One of a process analyzer’s
“Quick analytical data can be one of the most effective ways most important benefits is its ability to
to detect and stop a potentially dangerous chemical reaction detect and measure process conditions
that may have the potential to endanger
inside a fluid system.” nearby workers and equipment.
Quick analytical data can be one of
the most effective ways to detect and
stop a potentially dangerous chemical
reaction inside a fluid system. An ana-
lyzer can detect media conditions that,
if left unattended, could rupture a pipe
or vessel and endanger personnel. This
benefit may justify the expense of qual-
 Figure 3: General cost estimate for analyzers installed in air-conditioned analyzer houses. ity process analyzers for use throughout
©2021 Swagelok. an entire system.
Additionally, many chemical pro-
cessing plants are beholden to local
profitability, so plants must consistently can be severely damaging to a produc- and federal environmental compli-
be producing to specified, or better, er’s reputation. By contrast, a perfectly ance requirements. For instance, con-
quality levels. good product may end up rejected sim- tinuous emissions monitoring systems
There is, however, a cost of produc- ply because an analyzer is out of calibra- (CEMS) and effluent water analyses
ing a product of too high quality — and tion. The tangible loss from the latter are legally required in many locations
analyzers can help eliminate this “give- scenario can be calculated based on around the world. Plants must install
away” by reducing random product plant data, but the cost of losing a cus- safety and environmental monitors
quality variations. Figure 2 illustrates tomer due to an off-spec product can regardless of their cost and return on
the concept. When product quality have larger ramifications. investment to comply with these kinds
variations are significant (shown by the A process analyzer that helps to miti- of regulations.
blue curve), a plant produces a higher gate either scenario can easily justify its
average quality for fear of making an expense and continued cost of owner- Calculating your return
off-spec product — but achieving this ship. It should therefore be taken into Before deciding on an analyzer pur-
level of quality will reduce throughput, consideration when demonstrating re- chase, combine all the associated ex-
increase production costs, or both. turn on investment. penses as a capital investment. Your
Operators can use analyzer measure- return figure is the resulting net cash
ments and process controls to reduce Plant safety stream over the lifetime of the analyzer.
the quality variation (green curve), In any industrial environment, the Common capital investment costs asso-
thereby driving the average quality safety of workers is always the highest ciated with analyzers often include:
down closer to the specification limit.
In this case, they will still be making
on-spec product, just more efficiently or
more copiously than when they are fo-
cused on higher average quality.
In any market, the return on invest-
ment for a process analyzer used for
control is calculable from the value of
increased throughput or the reduction
in operating costs.

Quality assurance
The accuracy of analyzer measurements
is vital to a producer’s profitability, and
poor analysis can have a significant
negative impact. A bad product that  Figure 4: Maintaining the reliable operation of sampling systems helps enhance the analyzer's return on investment.
makes its way into a customer’s hands ©2021 Swagelok.

26 P.I. PROCESS INSTRUMENTATION | NOVEMBER/DECEMBER 2021

 • Sample conditioning systems.
• Rack, panel, open shelter or HVAC “The accuracy of analyzer measurements is vital
analyzer housings. to a producer’s profitability, and poor analysis can have
• Probes, pumps and field stations.
• Installation, including fast loops,
a significant negative impact.”
and disposal arrangements.
• Startup and commissioning. A return on investment figure can be An original version of this article appeared
• Initial spare parts stock. calculated with a spreadsheet function on the Swagelok Reference Point blog here:
— many plants can anticipate at least a www.swagelok.com/en/blog/calculating-
Figure 3 provides a general estimate of 50% return. If making the case to man- roi-process-analyzer-technology.
the costs associated with various kinds agement, ensure that you can support
of analyzers installed in air-conditioned your findings and can speak to how an- Karim Mahraz is a product manager, Analyti-
analyzer houses. For a simple estimate, alyzers can make a positive impact on cal Instrumentation, with Swagelok Company.
first add up your analyzer costs and mul- your system and its profitability.
tiply by three for the material costs; by Working with a reliable supplier in
four for the cost of a fully commissioned sourcing your fluid system compo-
system; or by five if including project nents can also be helpful in determin-
management from your site. This simple ing the potential benefits of upgrading Find more online at
calculation can work well for a variety of analytical equipment. Process analyz- piprocessinstrumentation.com
on instrumentation.
analyzer types. Note: This estimate may ers are, once again, an investment that
be high for more expensive NMR analyz- should be considered. If integrated
ers, or low for inexpensive oxygen, pH correctly, operators will be satisfied
and conductivity analyzers. with the results.

Check Valves
From drinking water…
• Sizes 1/4” to 2”
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• Up to 260°F
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Neoperl, Inc. | Waterbury, CT

[email protected] | www.neoperl.com

NOVEMBER/DECEMBER 2021 | piprocessinstrumentation.com 27

2102PI_SpitzerBoyesFlow 1 12/15/20 2:44 PM
2105PI_Neoperl.indd 1 3/31/21 1:03 PM
 MONITORING

Maximize machinery life with

lubrication and IIoT
Instrumentation such as sensors, differential pressure
switches and flowmeters should be considered when
evaluating ways to leverage IIoT for lubrication management.
By Ian Miller, Motion

s the process manufactur- for a piece of equipment’s operating con-

A ing world takes advantage

of innovations spilling out
of the tech sector, the In-
ditions and use that, along with live feed-
back, to make recommendations.
Also consider that this facility scans
dustrial Internet of Things (IIoT) con- in all products at the shipping depart-
tinues to grow rapidly. The days of timers ment and scans them out of stores when
and relays are quickly disappearing, as removed by maintenance personnel, all
is the practice of reading the prover- via QR codes. That same AI could detect
bial “tea leaves” to plan maintenance if the wrong oil or filter is used (based
activities. Instead, new technologies on the QR information) or monitor the
empower integration of plant-wide in-service lubricant to evaluate ISO
control systems with condition monitor- cleanliness targets. This data could then
ing that enables real-time passive and determine if the filter element’s micron
active maintenance. and beta rating needs to be improved.
Picture building an algorithm based After identifying all of this, the system
on a parameter set to monitor and could automatically order new filters
adjust lubrication in real time for a and schedule that filter’s installation —
sensitive/critical piece of equipment. all without the input of anyone at that
In the past, this would be impossible facility. It is easy to see the potential.
to accomplish — today, it is a reality. This may seem to be a bit pie in the
Now, imagine that same parameter set sky. It is, however, the dream that in-
adjusted in real time by artificial intel- dustry is pushing toward and the vision
ligence (AI) based on historical data to that is driving many of the advances
extend the equipment’s life. As machine coming into the market today. Here are
learning (ML) and AI start to permeate a few instruments and technologies to
our industry, these “passive” or auto- consider when evaluating ways to lever-
mated means of real-time maintenance age IIoT for lubrication management.
are becoming the norm. Particle counters: A great tool to
Consider that same AI assisting with ensure the cleanliness of oil. Mostly seen
activities to maximize lubricant life. for larger hydraulic systems, these sen-
These actions may include scheduling fil- sors will often also provide temperature
ter changes, evaluating a fluid’s remain-
ing life or determining when to change
filter ratings or oil type. Using IIoT tech-  Figure 1: This filter cart has an internally
plumbed particle counter to display ISO/SAE
nology, for example, a particle counter counts and temperature. This allows for real-time
at an AI-enabled “smart facility” could monitoring and verification of lubricant integrity
actively manage maintenance activities. during equipment installations and servicing.
This system would hold historical data All images courtesy of Motion

28 P.I. PROCESS INSTRUMENTATION | NOVEMBER/DECEMBER 2021

  Figure 2: For an overland conveyor application,
this automated grease system uses a pressure
transducer to identify that a lube cycle has occurred
and that the system is operating as expected.

rolling elements can eventually gener-

ate heat and indicate that the greasing
intervals/volumes need review.
Differential pressure switches/
transducers: These have been avail-
able on the market for many years and
are commonly used to monitor the dif-
ferential pressure across a filter element,
identifying when that element will need
replacement. (Figure 2.)
Oil condition sensors: Several of
these sensors come in one package
and typically monitor for water satura-
tion level, temperature and changes of
readings and typically display ratings in electric conductivity and dielectric con-
ISO, SAE or both formats. (Figure 1.) stant. This can be a good tool kit, par-
Conductivity sensors: Most oils ticularly for gearing applications. Today,
have low conductivity, and monitoring some integrate this as a kind of “check
for increases can give a good indication engine light” on large gearboxes.
of component wear. The abrasion of con- Flowmeters: These are a great way
ductive materials in a piece of equipment to measure the delivery of lubricant vol-
will lead to an increase of conductivity ume, both for kidney loop/oil spray ap-
for the oil. As the level of suspended con- plications and grease quantity monitoring
ductive impurities rises, so does the indi- for a critical asset.
cation of mechanical wear. Step changes Proximity switches: Commonly
over time can show — especially when used on series progressive auto lube
supported by other monitoring means systems, proximity switches ensure
— that a piece of equipment needs to be that the metering block has cycled. This
scheduled for service. system style is susceptible to jamming
Water saturation sensors: Adding when contaminated. Using a proxim-
water to lubricants reduces lubricity and ity switch on the cycle pin can identify
has other detrimental effects, such as in- failure while measuring the grease dis-
creased varnish. A water saturation sen- pensed in each cycle.
sor allows you to monitor levels and act
as needed to correct for water egress into Conclusion
a system. Monitoring for step changes can As machine learning and AI usage
also indicate things like failed oil coolers grows across the process industries,
that rely on process water for cooling. those who invest in these technologies
Temperature sensors: Reduction in will be the ones to reap the rewards.
lubrication has the obvious effect of in-
creased friction. As such, monitoring for Based out of Calgary, Ian
temperature can reveal problems with Miller, P. Eng., is a national
the operation of critical assets. Some- services business develop-
what counterintuitive, however, add- ment manager for Motion. He
ing too much lubricant can also lead to has over a decade of hydraulic and electri-
temperature increase. A good example cal experience in the field, including system
would be overgreasing bearings. The design, troubleshooting, on-site installations
increased pressure and friction on the and technical training/support.

NOVEMBER/DECEMBER 2021 | piprocessinstrumentation.com 29

 P R O D U C T GAS INSTRUMENTATION

FOCUS
Send products for consideration in this section
to [email protected]

thermal flowmeter
Fluid Components International (FCI)’s ST100 Series Thermal Flow Meter features
repeatability in measuring NH3 under harsh operating conditions. It has a standard
wide flow turndown ratio of 100:1 (up to 1000:1 based on application), and the ability
to measure mass flow instead of volumetric flow. The ST100 Meter can be factory
calibrated to measure almost any popular process gas as well as mixed gases.
The technology is suitable for use in wet and dirty gas applications, having no small ports
prone to fouling. The basic insertion-style air/gas meter features a thermal flow sensing
element that measures flow from 0.25 up to 1000 SFPS with accuracy of ±0.75% of reading,
±0.5% of full scale. Whether the output required is 4-20 mA analog, frequency/pulse or
advanced bus communications, the ST100 Series meets integration needs.

www.fluidcomponents.com

gas analyzer
Emerson’s chemiluminescence gas analyzer with new digital
communication capabilities enables reliable monitoring of
nitrogen oxides (NOx) emissions. The Rosemount XECLD
Process Gas Analyzer leverages the digital architecture of the
Rosemount X-STREAM Enhanced (XE) suite of continuous gas
analyzers to offer a full range of web-based communication
ultrasonic flowmeter
capabilities, including secure, remote connectivity without
FLEXIM’S FLUXUS F/G831 is a new ultrasonic system that the installation of additional software. This simplifies access
measures liquids, gases and steam and is approved for to analyzer health and actionable process information to help
operation in ATEX/IECEx Zone 1. The flow measurement is operators comply with environmental regulations. Designed
carried out nonintrusively with ultrasonic transducers mounted for optimum reliability and low cost of ownership, the gas
on the outside of the pipe. FLUXUS F/G831 has two intrinsically analyzer utilizes chemiluminescence measurement technology
safe (Ex-ia) process inputs for connecting pressure and with a thermoelectrically cooled, solid-state detector
temperature sensors. This allows the transmitter to directly assembly to ensure highly stable measurement performance
determine the output mass flow or standard volumetric flow and a longer operating life. In addition, the analyzer eliminates
rate. Inside the hermetically sealed enclosure, a digital signal vacuum pumps often used in chemiluminescent instruments,
processor ensures the highest measurement performance. significantly reducing a potential source of vibration.
The integrated disturbance correction ensures good measuring www.emerson.com
accuracy even at unfavorable measuring points. The high-
performance processor supports fast switching between two
measuring channels. Synchronized channel averaging enables
immediate compensation of measured value fluctuations
resulting from disturbances of the flow profile due to turbulence
or difficult inlet conditions.

www.flexim.com

30 P.I. PROCESS INSTRUMENTATION | NOVEMBER/DECEMBER 2021

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When it comes to
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TRENDS IN
GAS FLOW
MEASUREMENT

TRENDS IN
GAS FLOW
MEASUREMENT
Calibrating Coriolis flowmeters
Page 16

Assessing liquid leakage

from shaft seals
Page 24

Overcoming control valve

trim selection challenges
Page 27

DECEMBER 2020 | piprocessinstrumentation.com Calibrating Coriolis flowmeters

Page 16

Assessing liquid leakage

from shaft seals
Page 24

Overcoming control valve

trim selection challenges
Page 27

DECEMBER 2020 | piprocessinstrumentation.com

The Measurement of Process Parameters

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Don’t forget the MEASURING 
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