Monitoring &

Maintenance
Advances in sensors and software
improve safety and asset integrity

Also Inside

Reverse flow in processes

operating under vacuum

Flowmeter diagnostics
to optimize efficiency

EPIC devices for

automation applications

JULY 2019 • Vol. XXIV, No. 7

www.flowcontrolnetwork.com
 AHR EXPO
PREVIEW
Page 28

FLUID
Density
The effects of
temperature and
pressure

Also Inside

Automating custody transfer

level measurements

Ultrasonic flowmeters for

HVAC monitoring

Performing a storage
tank risk assessment

JANUARY 2019 • Vol. XXV, No. 1

www.flowcontrolnetwork.com

Connect
SOLUTIONS FOR FLUID MOVEMENT, MEASUREMENT & CONTAINMENT

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GF Piping Systems

9950 Dual Channel Type 586 Pressure

SmartPro Transmitter/ Regulating Valve
Controller GF Piping Systems is pleased to introduce the innovative modular
5 series pressure regulating valve (PRV). The modular design allows
• Independent Dual Channel Multiparameter Flow, pH/ORP, users to easily change configurations. The valve can be changed from
Conductivity/Resistivity, , Pressure, Temperature, Level/ a back-pressure valve to a reducing valve by simply changing out the
Volume, Salinity, Dissolved Oxygen, Other (4 to 20 mA) cartridge. Springs can be added or removed to meet optimum pressure
ranges. In addition, the modular design allows for easy and quick
• Available in two voltage options: 10.8-35.2 VDC, or
maintenance for scheduled shutdowns. An online tool is available,
100-240VAC/10.8-35.2 VDC
making sizing a breeze. All sizes are molded, which eliminates
• 2 Passive 4-20mA Loop Outputs Standard inconsistencies found in machined valves. The type 586 is the
pressure-retaining or back-pressure valve; it maintains back pressure
• Choice of up to 4 Relays – Dry contact or Solid State and can act as a pressure relief valve. The type 582 valve is the
pressure reducing version.
• Optional Two mechanical relay module with four binary
inputs for up to four more sensing points • No re-torqueing needed
• Advanced Boolean Relay Logic
• Modular
• Derived Functions : Ratio, Difference, Sum, % Rejection,
% Recovery • Online tool makes sizing a breeze
• Onboard Clock and Calendar for Scheduled Events • 100% molded design means
The 9950 SmartPro Transmitter takes a simple approach to consistent quality
modularity. Choose from DC powered only or AC/ DC powered
Union style bonnet
system. The 9950 is ready to run out of the box with its standard eliminates the need
two 40-2omA passive outputs. Add optional relay modules and to re-torque
binary inputs, and transform your SmartPro in to a two channel
controller. With on board clock/calendar, derived functions,
and advanced relay operation, you have seemingly countless
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2270 Level

Reconfigure valve function

by changing cartridge

Molded body
available in PVC,
CPVC, PP, PVDF
2551 Ultrasonic

GF Piping Systems
9271 Jeronimo Road, Irvine, CA 92618
Phone (714) 731-8800 • Toll Free (800) 854-4090 • e-mail: us.ps@georgfischer.com www.gfpiping.com
 Remain compliant and minimize risk.

“We help you focus on producing higher-quality

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provide a global calibration program, standardized
for both on-site and laboratory calibration.”

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Calibration Manager

Learn more about our calibration capabilities:

go.endress.com/us/calibration-capabilities
Table of Contents | July 2019 • Vol. XXV, No. 7

Cover Series
Monitoring & Maintenance
12 A primer on IIoT architecture
for holistic tank monitoring
By Albert Behr, BehrTech
With next-generation sensing and wireless technologies,
tank monitoring encompasses level measurement
as well as leak detection, structural integrity and
tampering detection.

16 Safely maximizing production capacity

By Christiane Lederer, Emerson Automation Solutions,
Rosemount Corrosion Monitoring
Running a plant or unit beyond its engineered design
12
capabilities takes a toll on equipment, but wireless
corrosion sensors can determine when safety or asset
integrity is at risk.

20 Monitoring mishaps: Identifying

production issues with
remote monitoring
By Mark Howard, EU Automation
Advances in software, sensing technology and data
collection improve how plant managers monitor 20 26
production for more efficient maintenance plans.

Features Departments
22 Implementing IIoT in process
industry applications 4 From the Editor
By Benson Hougland, Opto 22
New approaches to IIoT installations are easier and less 6 News & Notes
expensive while also providing improved cybersecurity.

10 Application Corner & Quiz Corner

26 Flowmeter diagnostics
optimize production
By Tonya Wyatt, Emerson Automation Solutions 31 Advertiser Index
The benefits of online diagnostic data collection
include improved personnel safety, time savings
and reduced costs. 32 FlowControlNetwork.com

Cover: TomasSereda/iStock

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2 | July 2019 Flow Control

Simultaneous
flow, pressure and
temperature measurement
WATERFLUX 3070 – electromagnetic water meter with integrated
pressure and temperature sensor
• All data directly available via Modbus RTU
• Important input for e.g. district zoning (DMA) and leak detection
• Battery or mains powered with battery backup
• CT: MI-001, OIML R49 up to DN600 / 24“
• No inlet/outlet runs needed

us.krohne.com/en/waterflux-3070

products solutions services

 From the Editor VICE PRESIDENT & GROUP PUBLISHER
MICHAEL C. CHRISTIAN
[email protected]

T
his month, we turn our focus on talks about using remote monitoring for ASSOCIATE PUBLISHER
monitoring, maintenance and the more efficient maintenance plans in pro- JIM SEMPLE | 908-963-3008
[email protected]
industrial internet of things (IIoT) cess plants. Next, you’ll find another case
EDITOR IN CHIEF
to improve processes. study of a facility that implemented an IIoT
MOLLY ROGERS
As plants continue to implement IIoT, solution, a new type of controller called an
[email protected]
more advances in technology and soft- edge programmable industrial controller (or
CONTRIBUTING EDITORS
ware are making it easier, less complex EPIC), to address challenges of complex- AMY W. RICHARDSON
and more cost-effective. In this issue, you’ll ity, security and cost. Opto 22's Benson [email protected]
read about how IIoT is transforming dif- Hougland describes how EPIC devices MARIE MCBURNETT
ferent operations. For example, the cover are capable of flattening the architecture [email protected]

story by Albert Behr, founder and CEO of required to transfer data from the field to a GROUP ASSISTANT EDITOR

BehrTech, covers tank monitoring for chemi- cloud-based or an on-premises application. DANIEL GADDY
[email protected]
cal and petrochemical plants and shows Lastly, Tonya Wyatt with Emerson
COLUMNIST
how a holistic approach enabled by IIoT can Automation Solutions wraps up this issue
DAVID W. SPITZER
not only provide level monitoring and leak with a discussion on flowmeter diagnos-
ART DIRECTOR
detection, but also structural integrity and tics that can help optimize production RYAN CARLSON
tampering detection by aggregating sensor and generate reports to document meter PRODUCTION MANAGER
data on an unprecedented scale. verification. And, columnist David W. AMANDA PORTER
These facilities that are using new IIoT Spitzer talks about reverse flow in his [email protected]

solutions are also beginning to see positive Application Corner. DISTRICT MANAGER

results. Christiane Lederer with Emerson, I hope you find the examples of IIoT JAY HAAS | 281-980-5831
[email protected]
Rosemount Corrosion Monitoring, shares solutions in this issue helpful for your
WEST COAST SALES
a case study of a refinery that installed operations, and if you’re experiencing suc-
MARK MALLOY | 224-234-8275
ultrasonic wall thickness sensors capable cessful results with an IIoT implementa- [email protected]
of taking continuous metal thickness read- tion, please feel free to reach out to me ACCOUNT MANAGER
ings and sending the data to a monitor- to share with our readers. LISA WILLIMAN | 518-322-6691
ing and historicizing system. Adding the Thanks for reading! [email protected]
sensors enabled the plant to monitor the DIGITAL BUSINESS DEVELOPMENT MANAGER
pipework for ongoing integrity problems, MICHAEL RING | 347-365-0641
[email protected]
and the data history showed how differ-
Molly Rogers MARKETING MANAGER
ent feedstocks were affecting metal loss.
JOHNSON BAILEY
Also in the cover series, read an article [email protected]
DIGITAL OPERATIONS MANAGER
from EU Automation’s Mark Howard who @FlowControl_Mag MARY BETH ROMANO
AUDIENCE DEVELOPMENT MANAGER
ANNA HICKS
SUBSCRIPTION & REPRINT REQUEST
fl[email protected]
metamorworks/iStock

CORPORATE TEAM
CHIEF EXECUTIVE OFFICER
CHRIS FERRELL
CHIEF OPERATING OFFICER
PATRICK RAINS
EXECUTIVE VICE PRESIDENT
SCOTT BIEDA

EDITORIAL ADVISORY
AD 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

4 | July 2019 Flow Control

News & Notes

Company news which pumps are usually made. Pleuger BP and Schneider Electric
Industries pumps rely on corrosion pro- sign five-year, global
The TASI Group continues tection and energy-efficient design to framework agreement
expansion with second maintain in harsher environments. BP has selected Schneider Electric, a
acquisition, Sierra provider of energy management and
Instruments Gardner Denver merges automation solutions, as one of its main
The TASI Group continues the growth of with Ingersoll Rand’s electrical contractors in a five-year global
its Flow Segment business with the recent industrial segment framework agreement. Under the terms
acquisition of Sierra Instruments, a global Gardner Denver Holdings Inc. and of the agreement, Schneider Electric will
company specializing in the manufactur- Ingersoll Rand have entered an agree- provide full-scope design and engineering
ing of flow measurement instrumentation. ment in which Ingersoll Rand will separate services, including optimization, project
This is the second acquisition finalized by its industrial segment and combine it with management and integration, procure-
The TASI Group in the last two months. Gardner Denver, creating a global provider ment and supply chain management,
Offering flow and test solutions to inter- of mission-critical flow creation and indus- and full support from commissioning
national markets, Sierra Instruments is trial technologies, called IndustrialCo. through to operations after startup for
comprised of two divisions: FLOW, head- Gardner Denver’s CEO, Vicente Reynal, the Electric Distribution System of BP’s
quartered in Monterey, California, and and executives from both companies, will upstream major capital projects awarded
AUTO, headquartered in Malvern, United lead IndustrialCo. to Schneider Electric.
Kingdom. The FLOW division manufactures IndustrialCo, which is expected to be
mass flowmeters and flow controllers for called Ingersoll Rand, will be composed ALTIVIA expands capacity
gas, liquid or steam applications. The AUTO of the entirety of Gardner Denver and for specialty chemicals
division builds complex, custom and inte- Ingersoll Rand Industrial, including Ingersoll ALTIVIA completed a new multipurpose
grated test facilities and world-class engine Rand’s pending acquisition of Precision production unit at its Phosgene Derivatives
and vehicle test automation systems. Flow Systems, which is expected to close Unit at La Porte, Texas. The facility will
by mid-2019. The board of IndustrialCo will result in a 30% increase in capacity for the
Dover acquires All-Flo be led by Gardner Denver Chairman Peter production of acid chlorides and chloro-
Pump Company Stavros. Michael W. Lamach, Ingersoll formates. The new reactor system and its
Dover Corporation completed the acquisi- Rand’s chairman and CEO, along with multipurpose design will expand ALTIVIA’s
tion of All-Flo Pump Company, Limited the current Ingersoll Rand executive team, continuous phosgenation capabilities and
(All-Flo), which is now part of the Pump will continue to lead ClimateCo, which is improve production flexibility to meet grow-
Solutions Group (PSG) unit within Dover’s expected to be renamed. ing and changing customer demands.
Fluids segment. Founded in 1986 and
headquartered in Mentor, Ohio, All-Flo Patterson Pump Company Statiflo expands in Australia
is a growing manufacturer of specialty approved through and New Zealand
air-operated double-diaphragm (AODD) Hydraulic Institute’s Engineering company Statiflo has added
pumps used in a wide range of industrial pump test program Australian business Piping and Automation
applications to transfer viscous, abrasive Patterson Pump Company is the latest Systems and New Zealand-based Asmuss
and hazardous fluids, sludges and slur- company to have its pump test labo- Plastic Systems to its growing network.
ries. The addition of All-Flo enhances ratory approved through the Hydraulic Statiflo, which has its headquarters in
PSG’s pump portfolio and expands its Institute (HI) Pump Test Lab Approval Macclesfield, Cheshire, United Kingdom,
geographic and channel reach. Program. The HI program helps pump and subsidiaries in the U.S. and Germany,
OEMs and other pump test laborato- designs and distributes static mixers and
Pleuger Industries supplies ries improve their current laboratory other process equipment. It exports to
Chile copper mine with procedures and policies by working more than 80 countries and supplies the
process water pumps with an experienced third-party audi- water and wastewater treatment indus-
Pleuger Industries supplied the Chilean tor to develop and maintain accurate, tries, oil and gas, petrochemical, food,
Collahuasi Mine with six pump units for uniform and repeatable pump testing pharmaceutical, pulp and paper sectors.
the filtration of copper concentrate. The protocols. The program also helps par-
10-inch pumps are used to dewater cop- ticipating organizations adhere to the Donaldson Company breaks
per sludge in the flotation process and requirements of the international test ground for new material
extract the copper concentrate. Process laboratory accreditation standard (ISO research center
pumps used in copper production operate 17025) concerning test measurement Donaldson Company, a manufacturer of
under extreme conditions because cop- equipment. The approved pump test lab filtration products, broke ground on a $15
per quickly oxidizes the materials from is in Toccoa, Georgia. million material research center at its

6 | July 2019 Flow Control

corporate headquarters in Bloomington, naval shipboard applications. Hoffer has ABB’s noninvasive sensor
Minnesota. With the addition of the cen- received many honors and awards over wins Gold in German
ter, Donaldson will add six researchers the years including North Carolina’s Innovation Awards
and engineers to the company’s head- Small Business Exporter of the Year and ABB was awarded Gold at the German
quarter's population of 1,100 employ- Schlumberger GOLD Level Supplier. Innovation Awards in the category
ees. The center is scheduled to open in Hoffer is the eighth member inducted “Excellence in Business to Business
November 2019. into the Hall of Fame whose honored — Electronic Technologies” for its new
members include: Gordon Arnold (Sierra noninvasive temperature solution. The
Siemens and TÜV SÜD partner Monitor Corporation), Wade Mattar device is the first temperature sensor of
on cybersecurity project (Schneider Electric), the late Richard its kind, providing a simple, noninvasive
Siemens and TÜV SÜD have come together Morley (commonly referred to as the means of measuring the temperature of
to address the growing risk of cyberat- father of the PLC), Robert Deane and an industrial process without sacrificing
tacks on critical infrastructure by collabo- Malcolm McQueen (Fluid Components the accuracy and responsiveness of con-
rating to provide digital safety and security International), the late Judy Stevenson ventional invasive sensors. Eliminating the
assessments, as well as industrial vulner- (Magnetrol International), and Dr. Peter risk of leakage, it enhances the safety
ability assessments to help global energy G. Martin (Schneider Electric). of people, plants and the environment.
customers identify asset risk and cyber- Moreover, customers can save up to 75%
security solutions. Under this partnership, Equilibar receives in engineering and installation costs — as
TÜV SÜD will offer digital assessments President’s “E” Award it takes away the need for inspections and
that incorporate Siemens as a provider of for exports has no impact on the plant’s process.
cybersecurity vulnerability assessments Equilibar, a manufacturer of specialty fluid
across the entire cyber asset manage- control instruments for research and People news
ment life cycle. The digital assessments industry, received the 2019 President’s
of industrial control systems in both the “E” Award for Exports during a May Viega executive joins PMI
oil and gas and power generation sec- 23 ceremony in Washington, D.C. The board of directors
tors (nuclear applications excluded) will be President’s “E” Award is the highest rec- Martin Knieps, director of technical mar-
vendor-agnostic, meaning they will not be ognition any U.S. entity can receive for keting for Viega LLC, was selected to
limited to customers using products and making a significant contribution to an join the board of directors of Plumbing
technologies manufactured and supplied increase in U.S. exports. U.S. Secretary Manufacturers International (PMI), the
by Siemens. of Commerce Wilbur Ross presented the not-for-profit association of plumbing
award to Jeff Jennings, Equilibar presi- product manufacturers and advocates
Awards & milestones dent, and Julie Detmering, exports and for plumbing products and technologies
customer service manager. Equilibar was meeting high safety and performance
Ken Hoffer inducted into recognized for its commitment to export standards. PMI group members pro-
Measurement, Control and expansion, including international certi- duce 90% of U.S. plumbing products
Automation Hall of Fame fications and global networking. and represent more than 150 brands.
The Measurement, Control & Automation Knieps, who joined Viega in 2006, has
Association (MCAA)’s Measurement, Hydraulic Institute names been active with PMI since 2015. He
Control and Automation Hall of Fame award winners at annual most recently served on its Advocacy/
achievement award was presented to conference Government Affairs Committee. Knieps
Ken Hoffer, chief executive officer of The Hydraulic Institute (HI) presented will serve a two-year term on the seven-
Hoffer Flow Controls Inc. Hoffer’s tech- awards for Lifetime Achievement, member board. Michael Martinez, product
nical achievements include the pioneered Member of the Year and Standards compliance manager at Delta Facuet Co.,
use of self-lubricated ball bearings in tur- Partner of the Year during the organiza- was also named to the board.
bine flowmeters. He developed the first tion’s annual conference. The Lifetime
HART-enabled device to receive official Achievement award went to Arnold Motion Industries names
certification by the HART Foundation and Sdano, senior director with Pentair. senior VP of Southeast Group
created the first portable field calibration The Member of the Year award went Motion Industries Inc., a distributor of
system for cryogenic flowmeters. Hoffer to Michael Mueller, manager of global maintenance, repair and operation
developed the first and only turbine engineering standards for Flowserve. replacement parts and a wholly owned
flowmeter to receive certification by the The Standards Partner of the Year award subsidiary of Genuine Parts Company,
United States Navy for use in nuclear pro- went to William Marscher, president named John Watwood as senior vice
pulsion service as well as to pass shock and technical director of Mechanical president of the company’s Southeast
and vibration certification for unrestricted Solutions Inc. Group. Watwood has an MBA from

www.flowcontrolnetwork.com July 2019 | 7

University of North Alabama and has a additional line sizes, increased accuracy of the market and are segmented into
Bachelor of Science in industrial distri- and broader flow ranges. Suppliers are multistage pump, single-stage pump,
bution/marketing from The University of also making battery-powered units, smaller submersible pump, sealless and
Alabama at Birmingham. With more than meter bodies for tight spaces, multivari- circular pump, and axial and mixed
20 years of experience in the industry, he able meters and self-monitoring or self- flow pump.
has worked in various positions with AIT, recalibrating meters. • Centrifugal pumps will dominate the
Fluid Engineering and SMC before join- Regulatory reporting requirements and market for industrial pumps. These
ing Motion Industries in 2008 as a fluid the need for continuous measurement pumps can handle varied pressure
power specialist based in Mississippi. without interruption are increasing the and have good load handling capa-
Watwood held branch manager positions value of redundancy in measurement. bilities with comparatively low main-
in Columbus, Mississippi, and Nashville, Vortex and turbine suppliers have brought tenance cost.
Tennessee, before earning a promotion to out flowmeters with two sensors and dual
division vice president, general manager flowmeters calibrated together. New dif- Key trends in the industry:
of the Nashville division in 2014. ferential pressure flowmeters offer fully • Growth in process manufacturing activ-
integrated orifice plates with multiple trans- ity will result in an increase in demand
Tru-Tech Valve names new CEO mitters. Dual turbine rotor designs offer for positive displacement pumps.
Tru-Tech Valve, a Pittsburgh-based dia- greater turndown flow range along with • Positive displacement pumps held a
phragm valve manufacturer, appointed enhanced accuracy. Redundancy is rapidly market share of 13% in the year 2018
Chetan Chothani as the company’s CEO. taking its place along with accuracy and and are forecasted to generate rev-
Tru-Tech is celebrating its 60th year as a reliability as key features of a flowmeter. enue of $10.71 billion in the year
manufacturer of diaphragm valves and one 2026 with an annual growth rate of
of the original licensees of the Arco-Wynn Industrial pumps market 5.3% throughout the forecast period.
diaphragm valve design. worth $90B by 2026 • With an increase in manufacturing
According to Acumen Research and activity, demand for aftermarket
Market updates Consulting, the global industrial pumps parts will benefit, majorly for the
market will reach around $90 billion chemical industry as they have harsh
Global flowmeter market to by 2026 and is expected to grow at a environments. FC
approach $8.85B by 2023 compound annual growth rate (CAGR) of
A new study from Flow Research, "Volume around 6% between 2019 and 2026. Send news and events for consideration
X: The World Market for Flowmeters, 7th Growing use of industrial pumps in vari- to Molly Rogers at mrogers@
Edition," finds that the worldwide flowmeter ous applications including wastewater endeavorbusinessmedia.com.
market totaled $7.06 billion in 2018 and is treatment and chemicals is likely to drive
projected to approach $8.85 billion by 2023. the market over the forecast period.
While new technology flowmeters are Demand for industrial pumps from process
Upcoming events
displacing traditional technology meters in and manufacturing industries is another
some applications, traditional meters are driving factor of the market. The rise in
ISA Energy & Water
still a major force in the flowmeter market. product energy pumps for the transporta- Automation Conference
New technology flowmeters — meters first tion and extraction of oil and natural gas Aug. 7–8
introduced after 1950 — include Coriolis, is having a positive effect on the market. Orlando
magnetic, ultrasonic, vortex and thermal Increase in crude oil price is also boosting isa.org
flowmeters. Traditional technology flow- the demand for the market as it fuels the
meters include differential pressure (DP), energy sector’s revenue. Turbomachinery &
positive displacement, turbine, open chan- Growing construction, automotive and Pump Symposia
nel and variable area flowmeters. manufacturing industries are expected to Sept. 9–12
Coriolis and ultrasonic flowmeters, raise the demand for industrial pumps in Houston
tps.tamu.edu
which are industry-approved for custody Asia-Pacific regions. The Indian govern-
transfer of both gas and liquids, are pro- ment has passed a policy for the promo-
WEFTEC
jected to experience the fastest growth tion of FDI investment in the oil and gas Sept. 21–25
rates over the next four years. sector. This will increase the production Chicago
In addition to growth factors related to of petrochemicals and polymers in the weftec.org
the oil and gas industry, product improve- country, hence propelling the demand in
ments in both new and traditional tech- this region. Increased investment in desali- PROCESS EXPO
nology flowmeters are contributing to the nation plants is also expected to increase Oct. 8–11
upward trend in the worldwide market. the sale of industrial pumps. Chicago
Some product improvements include Further key findings from the report suggest: myprocessexpo.com
modern materials for meter parts or liners, • Centrifugal pumps hold a major share

8 | July 2019 Flow Control

What’s the safest way
to climb a ladder?

Don’t.

Use remote monitoring sensors to view asset

measurements from a safe location.

Learn more: Fluke.com/ConditionMonitoring

Improve safety by deploying condition monitoring sensors that

automatically upload measurements to the cloud. View asset
data via smart devices anywhere there’s an internet connection.
©2019 Fluke Corporation.
6012214a-en
 Application Corner
By David W. Spitzer

Part 2: Measuring under vacuum:

The phenomenon of reverse flow

L
ast month, I mentioned three situ- have the mechanical integrity to operate
ations that one should carefully in a full vacuum.
consider: operation under vacuum, Reverse flow is another phenomenon
measuring downward liquid flow and that can occur in some processes oper-
gravity flow. Let’s continue to discuss ating under vacuum. Normally, liquid will
operating under vacuum. flow downward by gravity. However, when a
Liquids exhibit a pressure loss and sub- vacuum is applied to a vessel, liquid may
sequent recovery as they flow through an flow upward from below — like drinking
obstruction in the piping, including many through a straw. This can cause strange
flowmeters. Given that operation is often occurrences, such as when a flowmeter
at or near the vapor pressure, it is pos- measures reverse flow while a process is
sible for the liquid to form bubbles when not operating, and one would think that
pressure is reduced, only to implode dur- there should be no flow. Careful attention
ing pressure recovery. This cavitation can should be given to whether a flowmeter
catastrophically damage flowmeters and in a given application should measure
other equipment, so flowmeter selection reverse flow or not.
should be performed carefully. Selection, There are many other idiosyncrasies
sizing and specification of control valves associated with measuring under vacuum,
(and their internals) should likewise be but measuring downward flow will be dis-
carefully performed. cussed next month. FC
In general, flowmeters should be
selected and sized to have a low pressure David W. Spitzer is a principal at Spitzer
drop. However, selecting, for example, and Boyes, LLC, which offers engineering,
a full-bore magnetic flowmeter with no focused market research, writing/editing
piping obstruction would comply with this white papers, strategic marketing consult-
preference, but particular models may ing, distribution consulting, seminars and
not be acceptable because their liners expert witness services for manufacturing
may not be suitable for vacuum service. and automation companies. Spitzer has
Therefore, it is common to specify flow- written more than 400 technical articles
meters and other instruments for vacuum and 10 books about flow measurement,
service to operate between -1 to 6 bar — instrumentation and process control. He
even when the process does not operate can be reached at 845-623-1830 or via
under pressure — to ensure that they spitzerandboyes.com.

10 | July 2019 Flow Control

 Quiz Corner What are the approximate pump speed, pressure
and mechanical load at 50% flow?

V
arious reference materials contain information at half flow. Similar calculations show that electrical
describing the Affinity Laws associated with reducing energy consumption would be approximately 99.9% less
the speed of a centrifugal pump. Mathematically, they at 10% flow.
show that: pump flow is proportional to pump speed; pump
discharge pressure is proportional to the square of pump Additional complicating factors
speed; and mechanical load on the pump is proportional to Not so fast — pumps almost always pump uphill, so the
the cube of pump speed. pump needs to overcome the static head of the piping
Using the information given, 50% flow would correspond system in order for the liquid to start to flow. If the static
to 50% speed, 25% pressure and 12.5% mechanical load. pressure needed to start flow is 64%, the pump must
Note that the mechanical load is closely related to electri- operate at 80% speed just to start flow — at which point,
strelov/iStock

cal energy consumption. its electrical energy consumption would be approximately

Of significant interest is that the electrical energy 50% to produce zero flow.
consumption would be reduced by approximately 87.5% If it looks too good to be true, it probably is.

www.flowcontrolnetwork.com July 2019 | 11

Cover Series: Monitoring & Maintenance

AvigatorPhotographer/iStock
A primer on IIoT architecture
for holistic tank monitoring
With next-generation sensing and wireless technologies,
tank monitoring encompasses level measurement as well as
leak detection, structural integrity and tampering detection.
By Albert Behr, BehrTech

C
hemical and petrochemical indus- approach is highly prone to human errors (IIoT) is transforming tank operations in
tries rely heavily on tanks and silos and fails to deliver round-the-clock visibility multiple ways. Incorporating next-gen-
in their operations to store large into current tank levels and conditions. eration sensing and wireless technolo-
bulks of fuels and propellants. The flam- Implementing a monitoring network with gies, IIoT remote monitoring networks
mable and hazardous nature of these industrial wired solutions is cumbersome are flexible, cost effective and easy to
materials can cause disastrous envi- and capital intensive. Running cables deploy and maintain. They can reach out
ronmental and financial impacts in the around complex industrial facilities is inher- to previously infeasible locations and con-
event of product release. As such, refill- ently dangerous and can lead to costly pro- nect a large number of sensing devices
ing or emptying storage chambers timely duction shutdowns. On top of that, many from geographically dispersed storage
and accurately is a necessity for not only tank farms are located in physically chal- tanks. By aggregating sensor data on
operational efficiency, but also safety man- lenging and inaccessible areas where power an unprecedented scale and granular-
agement. At the same time, companies supply is constrained or absent altogether. ity, such an IIoT architecture empowers
need to constantly check on the structural Even when possible, wired networks limit a holistic tank management approach —
integrity of tanks and watch out for illicit the number of data points and restrict any from level monitoring and leak detection
activities like tampering and theft. changes such as adding new tank connec- to integrity check and fuel theft detection.
Traditionally, tank monitoring has been tions or moving around existing tanks.
a labor-intensive process with workers Fluid level monitoring
traveling throughout tank farms for visual A holistic tank monitoring Ultrasonic or noninvasive capacitive sen-
inspection and manual data readings. system enabled by IIoT sors attached to wireless transmitters can
While requiring significant labor hours, this Today, the industrial internet of things measure and communicate liquid level

12 | July 2019 Flow Control

 By deploying vibration and motion sen-
sors, operators are instantly informed of
any dubious activities on storage tanks,
especially at night. To increase the reli-
ability of the automated alert system,
these sensors could also work in concert
with level readings that signal unusual
loss in fluid mass.

Figure 1. Key aspects of a holistic tank monitoring system. All figures courtesy of BehrTech IIoT architecture and key
network considerations
data to the control center located kilo- workflows to mitigate dire consequences An IIoT architecture for holistic tank moni-
meters away from the tank farm. With of tank failures. toring starts with effective data capturing
data on tank capacity, filling rate and Taking one step further, smart sensors and communications at the edge. Tank
required time for a field trip, operators can be installed to check on the struc- sensors can either be attached to wire-
can define the permitted threshold for the tural health of tanks round-the-clock for less transmitters or already have built-in
liquid level in each tank. Once the fluid anticipation and prevention of poten- connectivity. Newer radio transmitters can
amount exceeds or falls below the speci- tial leakages in the long run. Wireless additionally interface with legacy systems
fied threshold, an alarm is automatically corrosion detectors are instrumental in such as programmable logic controllers
triggered for timely dispatch of trucks to detecting wear and tear like reduced wall (PLCs) to extract various tank-related
empty or refill the respective silos. For thickness over time due to abrasion. operational data. Once captured, data
tanks containing feedstocks, real-time Simultaneously, vibration sensors can from various sources is then wirelessly
level data assists in effective inventory diagnose unwanted events such as jolted transmitted to a remote IoT gateway. It
planning to avoid out-of-stock conditions tanks caused by nearby pickup vehicles, is then reformatted and forwarded to the
that lead to expensive production halts. while temperature readings help moni- users’ preferred data systems and appli-
By effectively aligning schedule and tor unusual chemical reactions that may cation platforms using backhaul connec-
routes of field trips with actual production cause structural instability. By leveraging tions such as Ethernet or wireless local
needs, operators can maintain optimum advanced analytic tools, conditions that area network (WLAN).
tank levels, eliminate emergency deliver- lead to failures can be identified over Different from the common perception,
ies and maximize delivery/pickup quanti- time. This allows operators to prioritize IIoT data is not necessarily pushed to a
ties. This translates into improved worker maintenance tasks based on the urgent third-party managed cloud all the time.
productivity and saved fuel costs while needs of specific assets. The most versatile architecture renders
preventing overfills and production down- data control and ownership to the end
time. On top of that, continuous level Tampering and fuel users. They can decide to which reposi-
measurements can help detect abnormal theft detection tory and management systems the data
changes in the fluid amount potentially Tanks used to store valuable commodities should be relayed — whether an on-
caused by malfunctioning valves or pump- are highly vulnerable to vandalism and premises central PLC and human machine
ing components. fuel theft. Despite the explosive dan- interface (HMI), a remote control server or
ger of fuel compounds, thieves are still a private cloud-based analytic platform.
Leak detection and structural prompted to use perilous tools like drills Due to the inherently difficult and
integrity control and blow torches to extract materials out demanding industrial environments,
More than just level monitoring, an IIoT of the containers. Beyond product loss, selecting the right last-meter wireless
architecture enables leak detection of the result of such an attempt may be a solution is crucial to harnessing the full
storage tanks to avoid catastrophic inci- disastrous fire with irreversible damages. benefits of such an IIoT architecture. When
dents. Vacuum and pressure sensors can
identify and alert a drop in pressure that
indicates hazardous leaks and material
release. Likewise, low-frequency acoustic
sensors can detect small structural events
such as delamination, crack initiation and
growth through generated sound waves.
Synthesizing various sensor data allows
for the development of an early warn- Figure 2. Sensor data is wirelessly transmitted to a remote IoT gateway where it is relayed to the
ing system and automated emergency user’s preferred data systems and interfaces.

www.flowcontrolnetwork.com July 2019 | 13

 evaluating different available options, a
number of factors need to be considered.

Power efficiency: The often-inconvenient

locations of storage silos mean that moni-
toring sensors are nowhere near a power
supply and need to operate on indepen-
dent batteries. Energy efficiency is, there-
Figure 3. IEEE 802.15.4 mesh topology versus LPWAN star topology fore, a prerequisite to avoid the costs and
hassle of frequent battery replacement
and recharge. In this regard, traditional
power-intensive solutions such as cellular,
WLAN and other high-bandwidth networks
often fail to deliver.

Precision Flow Measurement Reliability: There are generally two

An ONICON Brand
requirements to ensure the reliability of
an industrial wireless network. First, it
must incorporate robust mechanisms to
resist co-channel interference from other
radio systems. Second, it must be able
to effectively function in hostile industrial
environments with significant glass, metal
and steel obstructions alongside asym-
metric topography.

Coverage and network capacity: A

last-mile communications solution pro-
viding extensive range and high scalability
can support massive endpoints distrib-
uted over a vast area, while requiring mini-
mal expensive infrastructure to reduce
total cost of ownership.

Choosing the viable

last-mile connectivity
iMAG Series Inline Magmeters EX Series Insertion Magmeters For battery-operated or energy-harvest-
Installs in Tight Spaces, Higher Accuracy Easy Installation, No Moving Parts ing IIoT sensors, low-power wide area
networks (LPWAN) and low-power mesh
solutions based on the IEEE 802.15.4
standard arise as two most viable, cost-
effective wireless options. LPWAN is
a family of technologies designed for
long-range, power-optimized transmis-
sions of low-throughput data using the
sub-GHz frequency bands. An LPWAN
node can transmit messages directly to a
remote gateway located kilometers away
while sustaining many years of battery
PE Series Low Flow Magmeter S Series Low Flow Paddlewheel
No moving parts, Chemically Resistant Afordable, Chemically Resistant life. On the other hand, IEEE 802.15.4
mesh solutions leverage a relaying net-
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14 | July 2019 Flow Control

technologies including WirelessHART, ISA- connectivity like LPWAN emerges as the the new commercial standard in LPWAN
100-11a and Zigbee, operate in the 2.4 backbone infrastructure to effectively technology for industrial IoT. With 30
GHz ISM band. communicate data at the challenging years of professional experience, Behr
While both LPWAN and IEEE 802.15.4 last mile. FC has led the commercialization, financ-
offer power, cost and range advantages ing and operational execution of some
when measured against legacy industrial of the world’s most famous technology
communications networks, they are not Albert Behr is founder and companies. For more information, visit
created equal. First, compared to the CEO of BehrTech, world- behrtech.com.
common 2.4 GHz radio frequency in wide licensee of MIOT Y,
mesh solutions, the sub-GHz radio waves
of LPWAN experience less attenuation,
bend farther around obstacles and bet-
ter penetrate through walls. As a result,
LPWAN offers more reliable connections
in structurally dense environments. The
Check Valves that Top
2.4 GHz airway is also more congested due
to significant electromagnetic noise from
existing industrial machines and networks.
Every List!
Second, the one-hop star topology in
LPWAN consumes less energy than the
mesh topology. Since nodes do not need
Long Life
to constantly stay awake to relay mes-
sages, they can fall into sleep mode
much longer to minimize power usage.
Miniature Size
Finally, due to the short physical range
of IEEE 802.15.4 protocols, users must
ensure there is an equal distribution of
Multiple
nodes in close proximity with one another. Configurations
As such, configuring and optimizing mesh
networks over a large area can be a
great challenge. Our check valves have earned
All things considered, LPWAN is a bet- high marks for reliability and
ter option for latency-tolerant industrial
remote monitoring use cases like tank
performance among engineers
management. For proven network quality, for liquid and gas flow control
scalability and long-term interoperability applications needing free flow in
with other components in the IoT ecosys-
tem, companies should consider LPWAN
one direction with reverse flow
technology that employs a software- prevented. These devices feature
driven approach and is built on rigorous an all-metal construction, long
industry standards.
operating life and a wide choice
Conclusion of cracking pressure options.
For safety and efficiency optimization, a
holistic tank monitoring approach extends
far beyond level monitoring to encom-
pass leak detection, structural health
management and tampering detection.
This approach calls for a flexible and
cost-effective architecture to scale with
granular, battery-operated data points
800.533.3285
over vast areas. As industrial wired net- www.OKeefeControls.com
works and conventional wireless options
may fail to deliver, next-generation IIoT

www.flowcontrolnetwork.com July 2019 | 15

Cover Series: Monitoring & Maintenance

zorazhuang/iStock
Safely maximizing
production capacity
Running a plant or unit beyond its engineered
design capabilities takes a toll on equipment,
but wireless corrosion sensors can determine
when safety or asset integrity is at risk.

By Christiane Lederer,
Emerson Automation Solutions,
Rosemount Corrosion Monitoring

P
rocess plants and the individual has become a critical skill to increase
units within them are designed limits while minimizing side effects and
to produce a specific product or equipment changes.
small group of related products to meet
market needs. This is especially true for Dealing with side effects
continuous processes such as oil refiner- One approach is to simply run pumps
ies where, once started, a plant may run faster, open valves and exceed limits in an
for years between turnarounds. In addi- effort to increase production. Naturally,
tion to having a small product slate, con- the effects will vary greatly, depending on
tinuous processes must operate within the nature of the plant, but the following
narrow capacity ranges to optimize heat are a few examples:
transfer and product yields. • Heating stages must run hotter to
Vessels, burners, pipes, pumps, valves transfer heat more quickly.
and other process and control equipment • Fluid flows through pipes and valves
are sized and selected to handle the types increase with higher velocities.
of feedstock and production volumes the • Residence time in reactors are reduced.
plant operator originally envisioned. As • The separating efficiency of fraction-
a result, it is not easy to make major ation distillation processes is lowered.
changes in output or accommodate
feedstocks with different characteristics. In short, effectiveness is reduced across
Unfortunately, in the real world, plants are all stages of the process. Equipment
often called upon to make these kinds wear also increases as more product
of changes. is forced through all equipment. These
This often requires changing equipment changes take their toll and will expose any
configurations to relieve some of the tight- weak links in the equipment configuration
est bottlenecks. Indeed, debottlenecking and construction.

16 | July 2019 Flow Control

 would need to be made to the process.
For example, some effectiveness of the
hydrocracker itself would be lost, which
would be realized in various places,
including the propane stream. A higher
amount of heavier unconverted oil would
be carried with the propane into the
hydrocracker stabilizer (see Figure 1). This
was normal to some extent, and much of
the unconverted oil would drop out in the
stabilizer, as had always been the case.
Nonetheless, at the higher production
level, far more unconverted oil went out
with the light ends and had to be removed
farther downstream.
The flow of light ends was split up and
sent through a series of air-cooled heat
exchangers, operating in parallel, to cool
Figure 1. The hydrocracker stabilizer overhead system removes heavier products from the propane stream. the stream and condense the remaining
All figures courtesy of Emerson Automation Solutions oil so it could be removed in a final sepa-
ration stage. Sour water also condensed
In some cases, a decision may have unit was key to the process, meaning at this point, so the separator produced
been made years ago to undersize equip- increasing production here was critical propane, unconverted oil and sour water
ment to reduce construction costs. to the overall project. as three output streams.
Whereas plant designers might have The company’s design engineering This part of the process did not have
tried to size piping to keep flow veloci- team carried out extensive evaluations to undergo any hardware changes to
ties manageable in an effort to maximize to determine feasibility, including haz- accommodate the production increase;
equipment life, in recent years, one com- ard and layers-of-protection analysis. however, the volume that the overhead
mon practice calls for smaller diameters The team ultimately concluded that the system had to handle increased signifi-
as a major cost-cutting effort. Increasing production increase was possible with cantly due to the overall separation effi-
velocity increases wear, thus simply mov- the existing equipment, but modifications ciency loss of the hydrocracker.
ing the increased cost out into the future.
Similarly, changing feedstocks can
cause less-visible problems. Opportunity
Light, sweet crudes can work well with inexpensive
crudes used as refinery feedstocks are carbon steel piping, but high total acid number
usually inexpensive for a reason: They
often contain contaminants in the form
(TAN) crudes can cause far more rapid metal loss.
of sediment or acids that can increase
equipment wear, corrosion and erosion
rates. For example, the alloys selected for
piping and vessels when the refinery was
built will have reflected the feedstocks
expected at the time. Light, sweet crudes
can work well with inexpensive carbon
steel piping, but high total acid number
(TAN) crudes can cause far more rapid
metal loss.

Case study: Refinery

A refiner in Europe called for an increase
of production at one facility by a major Figure 2. The header takes eight outputs from the
factor. This location already had a high heat exchangers and combines them into one line
for the separator inlet. The leak occurred at the
conversion capacity, so the addition was point of highest flow rate.
an enormous challenge. Its hydrocracker

www.flowcontrolnetwork.com July 2019 | 17

 future. Would the existing header last long
enough to reach a shutdown?
To determine the existing header’s con-
dition, the evaluation team installed five
ultrasonic wall thickness sensors at
strategic points (see Figure 3) where the
liquid streams passed through different
velocity stages. The total sensor instal-
Figure 3. Adding
lation project costs were approximately
Emerson’s corrosion 25,000€; however, given the production
sensors at strategic value of the unit at about 1 million € per
points determined the
existing wall thickness
day, it was regarded as a minor expense.
and how quickly the Emerson’s corrosion technology uses
metal was eroding from a permanently mounted ultrasonic sen-
the inside.
sor capable of taking continuous metal-
thickness readings and sending the data
Unexpected side effects at the final outlet, which is exactly where to a monitoring and historicizing system
After four years of operating at the higher the leak formed. The corrosive nature of via an IEC 62591 WirelessHART network
production level, plant management was H2S was considered a contributing factor, (see Figure 4). Readings from individual
convinced that the overall effort proved to but erosion caused by high liquid velocity sensors can be analyzed throughout time,
be a success with appropriate increases was the main cause. making it possible to watch metal loss
in profitability. A new equilibrium was After performing a better repair, the as it happens.
reached, or so they thought. team considered longer-term options.
A problem revealed when the increased Should they continue operating with the Results
liquid velocity caused by the higher flow existing carbon steel header, or shut down The sensors indicated significant metal
rate resulted in erosion in the complex and fabricate a new header out of stain- loss in the header from a combination
header created to join the outlets of the less steel as quickly as possible. of erosion assisted by corrosion. In the
air-cooled heat exchangers. At this point, The obvious issue that needed to be worst areas, the pipe wall was thinning
the eight individual heat exchanger outlets first addressed was the overall condi- by 2 millimeters per year. The evalua-
had to be joined into one (see Figure 2). tion of the header and the degree to tion of the header performed four years
One day, operators discovered a plume which it had already eroded. Was this earlier had not fully taken this issue into
of liquid propane with high H2S content leak merely one that would be followed account, which is why the carbon steel
shooting out of a newly formed leak in by many more? Even if they decided to header had been left in place.
the header, creating serious safety and replace the header, fabrication would take Adding the nonintrusive wireless cor-
environmental issues, not to mention weeks. Installing it would require a shut- rosion monitoring sensors allowed the
product loss. down of the unit, but continuous produc- engineers to determine the condition of
Fortunately, the problem was discov- tion was scheduled for the foreseeable the header and watch any subsequent
ered before the propane found an ignition
source. The unit was shut down briefly
so an externally mounted clamp could
be installed before resuming operation.

Seeking the cause

Engineers trying to understand what hap-
pened returned to the analysis performed
four years earlier to determine if some
unanticipated operational factor had
changed or if the analysis had simply
been wrong. The original carbon steel
header had been left in place because
the conclusion at the time suggested the
material was adequate for the service. Of
course, the liquid velocity was highest at Figure 4. Wall thickness measurements can be historized and watched throughout time,
the point where all flows came together allowing the effects of high TAN crudes to be monitored.

18 | July 2019 Flow Control

deterioration as it happened. This pro- point will fail and begin to leak or worse. when much of the savings is lost to plant
vided an accurate indication of how A refinery that has been in operation damage and resulting production losses.
much time remained before another for some years will usually contain a mix- Having current asset health data trended
leak developed or a more catastrophic ture of new and old equipment. Piping over time makes the difference toward
failure occurred. Fortunately, enough and vessels in one part of a unit may more informed operating decisions. FC
time existed to fabricate a new stain- be stainless steel but carbon steel in
less steel header without extraordinary another. Liquid velocities are not always
rush costs and to install it during the consistent, so different wear factors must Christiane Lederer config-
soonest available planned shutdown. be considered. ures corrosion monitoring
The true value of the installation was in Adding corrosion wall thickness sensors solutions and supports the
avoiding far greater costs for expedited in strategic locations can enable a plant North American downstream customer
design and fabrication of a new header to monitor what is happening with base as part of the business development
and production disruptions for a shut- pipework by providing an accurate and team for Emerson Automation Solutions
down not yet warranted. continuous picture of ongoing integrity corrosion monitoring. She joined the com-
threats. When this type of data history is pany in 2014 as a sales engineer, bring-
Dealing with opportunity available, it is easy to see how different ing a wealth of experience gained while
feedstocks feedstocks affect metal loss. The sen- working in the refining industry, most
Saving costs by using cheaper grades of sors and associated software can even recently at OMV’s Schwechat Refinery.
crude oil, potentially carrying serious provide alarms if corrosion moves past Lederer holds a doctorate in mining and
contaminants, is a gamble many refin- a predetermined rate. metallurgical sciences and a master’s
ers choose to take. Most facilities can This data is insightful for production degree in process and environmental
tolerate processing these feedstocks for planners to determine when changing engineering, both from Austria’s University
some period, but ultimately, the weakest feedstock makes economic sense or of Leoben.

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www.flowcontrolnetwork.com July 2019 | 19

Cover Series: Monitoring & Maintenance

Courtesy of EU Automation
Monitoring mishaps:
Identifying production issues
with remote monitoring
Advances in software, sensing technology and data collection improve how
plant managers monitor production for more efficient maintenance plans.
By Mark Howard, EU Automation

M
any years back, canaries were for humans working in industrial environ- according to a study by United Airlines,
widely used in coal mines to ments too. Unlike the life-threatening 89% of mechanical failures are com-
detect the presence of car- risks associated with historical process- pletely random and therefore cannot be
bon monoxide. Due to their size, these ing industries, most of today’s risks are avoided using a scheduled maintenance
birds would succumb to the gas before related to the financial implications of plan. The solution: condition monitoring.
workers, allowing humans to escape the unplanned equipment downtime. Of course, condition monitoring is not
mine unscathed. Risk detection in mod- Downtime in processing is often a new phenomenon. As the name sug-
ern industry, however, is a much more caused by the failure of equipment. gests, this method of maintenance sim-
sophisticated affair. This downtime is often exasperated by ply refers to monitoring the condition
Good news for our little yellow friends, either an inability to repair equipment of equipment and performing repairs
the tradition of using canaries in coal or no method of accessing replace- as required.
mines came to an end in 1986. That ment parts. Plant managers have long While the practice of condition monitor-
said, working conditions have improved implemented scheduled maintenance ing is not groundbreaking, some of the
not only for the sentinel species, but also strategies to lessen the risk. However, technology available to implement this

20 | July 2019 Flow Control

 Combining real-time performance data with historical
performance data of the motor, the SCADA system could
identify an incremental decrease in performance.

practice is new and innovative. In fact, underlying issue that may lead to an is key to minimizing downtime overall.
one of the areas showing significant eventual breakdown. However, remote monitoring is not the
advancement is the field of remote At this stage, a maintenance engineer only way to lessen the damage. Taking
monitoring — the practice of monitoring should be deployed to investigate the the motor failure as an example, restart-
production remotely. cause of the decrease. There are a myr- ing production also relies on the plant
When miners used canaries for poi- iad of reasons that could cause motor manager sourcing a replacement motor.
sonous gas detection, some facilities slowdown, including poor ventilation, dust Establishing a relationship with an indus-
would lower caged birds into tunnels and contamination and improper lubrica- trial parts supplier is recommended to
before a worker would enter. This low- tion. Inspection at this stage allows the further streamline this process.
ered the risk of exposing miners to problem to be handled rapidly. It may be
gases by keeping them at a safe dis- a quick fix, such as the removal of dust, Conclusion
tance. Again, today’s production facilities which can be easily reversed before it Modern production facilities do not pres-
do not pose such threats, but technol- becomes a costly motor failure. ent the same life-threatening dangers as
ogy does allow for plant managers to Motor failure in fluid handling could the coal mining environments of earlier
monitor the problems in production from bring an entire pump system to a stand- centuries. Today, monitoring techniques
any location. still. The financial implications of this are sophisticated enough to identify even
Advancements in supervisory control downtime will depend on the exact indus- the slightest changes in production, effi-
and data acquisition (SCADA) software try. However, according to a report by ciency and output data, allowing plant
is playing an essential role in improving Aberdeen Group, unplanned downtime managers to identify and eliminate many
remote monitoring. Traditionally, SCADA can cost businesses up to $260,000 risks before they occur.
software would simply allow plant man- an hour. Canaries became synonymous with
agers to monitor production. However, Sometimes, failures cannot be avoided. the coal mining industry before their
an increase in sensors and intelligent For instance, if a motor was to fail due roles were rendered redundant in 1986,
machinery has enabled this software to to rapid overheating, a preempted prob- following the introduction of handheld
collect a greater plethora of data, thus lem could not have been identified by gas detectors. Processing facilities
enhancing remote monitoring. SCADA’s predictive analytics. Using the are experiencing a similar, albeit more
For example, a SCADA system in a fluid same SCADA technology, however, a plant advanced, change. Advances in SCADA
handling application identifies an error manager would be alerted immediately, software, combined with sensing tech-
related to the performance from a motor. should a motor break down. This is where nology, is improving how plant man-
In a fluid handling system, the motor the advantages of remote monitoring agers monitor sites, allowing for more
drives the amount of electrical power come to fruition. efficient maintenance plans and, in turn,
needed to perform efficiently. However, as When a motor breaks down, there is decreased downtime.
far as the plant manager can determine, no reversing the failure. The only solution Without a canary in sight. FC
pump output has not decreased and there is to identify the failure promptly and take
are no obvious signs of a failure. So, is steps to replace the equipment. SCADA
there really a problem? software can provide plant managers with Mark Howard is U.S. country manager at
Combining real-time performance production alerts from numerous devices — industrial parts supplier EU Automation.
data with historical performance data whether that is a human machine inter-
of the motor, the SCADA system could face (HMI) on the shop floor, a desktop
identify an incremental decrease in computer or mobile device. Mobile acces-
performance — even by the smallest sibility ensures that a plant manager is
amount. This is known as predictive ana- alerted immediately, regardless of if they MORE For more on monitoring
lytics. Now, this is not to say the motor are on-site, at home or out for lunch.
ONLINE and maintenance, visit
is on the brink of failure, but this small Reducing the time between equipment
flowcontrolnetwork.com
decrease in productivity could reveal an break down and identifying the problem

www.flowcontrolnetwork.com July 2019 | 21

Features: Control & Automation

Implementing IIoT in process

industry applications
New approaches to IIoT installations are easier and less expensive
while also providing improved cybersecurity.
By Benson Hougland, Opto 22

I
IoT installations are increasing across
the process industries, but current
solutions are often too complex and
expensive. The following example from
a glass products manufacturer in Ohio
describes the challenges and solutions
for implementing an IIoT project.
A critical aspect of the project was
transferring existing data from its manu- Figure 1. Opto
facturing lines to a web-based user inter- 22’s groov
EPIC device,
face (UI) already in use by the company’s released in
management team. May 2018
The existing UI displayed production with quarterly
updates since
goals and sales from the company’s then, is the
enterprise resource planning database, first of many
and the team needed to add real-time expected in
this class.
production figures for comparison. With
All images
this information on hand, they could make
courtesy of
better decisions regarding production. Opto 22
At first glance, this seemed to be a
simple problem because all the required
hardware and software was in place — Field devices on the manufacturing lines data acquisition (SCADA) system. These
with secure data transfer from the pro- were wired to local programmable logic systems required the engineers to con-
duction lines to the UI as the only new controllers (PLCs), handling field device figure data tags, drivers and polling rate
item. But further examination revealed values in raw count format. Getting data assignments.
a host of difficulties in terms of cost, from the PLCs required device-specific Then, working with their information
complexity and cybersecurity. communication drivers. The engineers technology (IT) department, the engineers
purchased and installed them, chose the also configured the HMI and the SCADA
Glass manufacturer desired points and mapped the points in system to transport the data to the com-
challenges a spreadsheet. Data in count format then pany database. Additional programming
The specific challenges faced by the glass had to be converted to engineering units. was required to make the data available
manufacturer were as follows, and many Next, the PLC data was networked to to supervisors.
of these issues are common across the a PC-based human-machine interface Although expensive and complicated,
process industries. (HMI) and a supervisory control and it worked. The engineers and the IT

22 | July 2019 Flow Control

Figure 2. Traditional methods of exchanging data between field devices and cloud-based or on-premises applications require many hardware and software components.

personnel could finally get back to other involves a lot of expense and middleware, applications, a new approach is needed
projects they had put on hold, but they including computers, gateways, drivers, to simplify connections and communica-
wished there had been an easier, less parsers, custom software, licenses and tion that does much more than a PLC or
costly and more secure solution. other add-ons. even a PAC.
The need for such a solution became As soon as data moves outside the What’s needed is a class of automation
urgent when the company realized the immediate network or off premises — for solutions that shrinks or eliminates the
management team needed more infor- use in the company computer network, middleware and lets users move data
mation from the manufacturing lines, as remote locations or on a tablet or smart- from where it is produced to where it
well as a way to make adjustments in real phone connected to the internet — middle- needs to be in fewer steps (see Figure
time, which would require two-way com- ware requirements increase and security 3). This new type of controller is referred
munication. In addition, new production concerns balloon. A typical configuration to as an edge programmable industrial
lines were being planned to manufacture to enable these communications requires controller (EPIC). Examining each part of
a different kind of glass. The new lines many components and significant configu- the EPIC acronym provides a more precise
would require control and, once again, a ration and programming (see Figure 2). definition of this type of controller.
complex architecture to share data with
the supervisors’ interface. Addressing challenges Edge: All data acquisition starts at the
and issues edge because that is where data is
IIoT issues Control system engineers are familiar with produced. It is best to collect and pro-
The challenges faced by this manufacturer PLCs and programmable automation con- cess this data directly at the source to
are common to many IIoT implementa- trollers (PACs). Both have been used and ensure accuracy, perform preprocess-
tions and involve three main issues: improved over many years, incorporating ing and prepare it for transmission. An
complexity, security and expense. Many capabilities formerly found only in propri- EPIC device sits at the edge and con-
IIoT or data-intensive automation applica- etary SCADA systems, adding communi- nects directly to sensors and actuators
tions become far more complex with more cations with Microsoft Windows-based through its I/O — the inputs and outputs
security risks than initially anticipated. The HMIs, running on standard Ethernet net- that gather sensor data and send con-
result is that the final cost and human works and so on. trol commands. It can also connect to
resource requirements are more than But for IIoT and other challenging appli- existing PLCs, HMIs and other control
many companies can expend or afford. cations, more is often desired from auto- system components to gather data and
Getting data from sensors and actuators mation systems. For these and future issue commands.
to the people who need to use that infor-
mation can be daunting. Bidirectional com-
munication for control can be even tougher.
An EPIC device sits at the edge and connects directly
Most industrial automation systems and to sensors and actuators through inputs and outputs
components use protocols and networks
that gather sensor data and send control commands.
proprietary or specific to automation, such
as EtherNet/IP, Modbus, Profibus, serial,
OPC or others. But commercial computers
and mobile devices use standard Ethernet
or wireless networks and open protocols
and standards such as TCP/IP, HTTP/
HTTPS, JSON and RESTful APIs (applica-
tion program interface).
Translating data between these dispa-
Figure 3. An edge programmable industrial controller can be used to replace multiple hardware
rate industrial and commercial systems
and software middleware components.
and then moving it where it is needed

www.flowcontrolnetwork.com July 2019 | 23

 Data from new sources can be added to the Because the EPIC device provides data
in standard engineering units, no conver-
system without middleware, and IIoT connections sion software is required. Once configured
are encrypted and authenticated. with plain-language names, I/O channels
are available automatically as tags in all
EPIC software, so no spreadsheets are
needed to keep track of points.
Incorporating production goals and
sales from the company’s database is
much simpler with an EPIC device, which
includes software such as Node-RED to
acquire this type of data through prebuilt
nodes. Data from all sources — PLCs,
company databases and sensors and
components wired to the EPIC device — is
easily made available to authorized users
in the EPIC’s HMI software.
Using EPIC devices also makes future
changes or expansion easier and more
secure. In addition to providing an HMI,
real-time control and connectivity to PLCs
and databases, an EPIC device can also
move data among OPC servers, cloud ser-
vices, cloud software and manufacturing
execution systems (MES) and enterprise
resource planning (ERP) business systems.
Figure 4. EPIC devices are often the best solution for collecting data from many different sources Data from new sources can be added to
and distributing it to a web-based user interface (UI).
the system without middleware, and IIoT
connections are encrypted and authenti-
Programmable: Like a PLC, an EPIC components such as solid-state drives are cated. New data, controls and authorized
device must be programmed for control. designed for long life. users can be easily added, with changes
Typical options include programming with pushed out to users, as shown in Figure 4.
familiar automation tools like flowcharting Controller: At heart, an EPIC device is
or any IEC 61131-3 compliant language, a real-time industrial controller designed Conclusion
including: to run control applications and pro- EPIC devices can provide real-time control
• Function block diagram (FBD) grammed with standard automation tools for all kinds of traditional automation appli-
• Structured text (ST) such as flowcharting, structured text and cations and can handle IIoT and data-
• Sequential function charts (SFC) even traditional ladder logic. The first of based tasks. These devices offer a simple,
• Ladder diagram (LD) many anticipated EPIC devices on the secure, maintainable and cost-effective
industrial automation market comes from solution for IIoT data communication by
Access is also available to an EPIC’s Opto 22 (shown on page 22). flattening the architecture required to
open-source operating system for cus- transfer data from the field to a cloud-
tom programming in languages such as Glass manufacturer solution based or an on-premises application. FC
C/C++, Java, Python and others. The glass products manufacturer already
uses PLCs to control its existing manufac-
Industrial: One problem with using PCs in turing lines. An EPIC device was installed Benson Hougland has 30 years
industrial automation is that an off-the-shelf to connect to these existing PLCs and of experience in IT and indus-
PC cannot be trusted to stand up to the communicate their data. trial automation. He drives
harsh environments often found in process However, the manufacturer did not need strategy for Opto 22 products connecting the
plants where only a much more expensive to purchase PLCs for the new lines they real world to computer networks. Hougland
industrial PC will work reliably. In contrast, planned to add. EPIC processors were used speaks at trade shows and conferences,
EPIC devices incorporate real-world auto- instead, connecting directly to sensors and including IBM Think, ARC Forum and ISA.
mation experience and are built to with- actuators to provide control, while com- His 2014 TEDx Talk introduces nontechnical
stand tough conditions. Industrial-grade municating data wherever it was needed. people to IoT.

24 | July 2019 Flow Control

2019
Innovation
Awards
Congratulations to the 2019 Innovation Awards nominees.
Voting is underway, and the winners will be featured in
the October issue.

Read about the nominees at

flowcontrolnetwork.com/innovationawards
Features: Flow Measurement

26 | July 2019 Flow Control

 Flowmeter diagnostics
optimize production
The benefits of online diagnostic data collection include
improved personnel safety, time savings and reduced costs.
Tonya Wyatt, Emerson Automation Solutions

S
everal years ago, in a Flow Control
article titled “Verifying Coriolis
Real-time or online quality checks, such as
flowmeter calibration,” Tom measurement of density, concentration or gas void
O’Banion with Emerson wrote that the
perfect flowmeter never drifts or wears.
fraction, can reduce the need for manual sampling.
It never needs zeroing. It measures in
mass units. It is immune to the effects of computer. Today, this can be accom- This may mean that workers are open-
changing fluid properties and fluid dynam- plished much faster and more efficiently ing valves, catching samples, transporting
ics, density, viscosity, Reynolds number, through advanced diagnostic capabilities them to the lab and testing the samples.
speed of sound, swirl and irregular profile. built into the device with the ability to All of this creates additional risk for expo-
It features advanced diagnostics capable transmit that information directly to a sure. Real-time or online quality checks,
of thoroughly checking any abnormal con- laptop, tablet or network. such as measurement of density, con-
ditions, perhaps even sending text mes- The benefits of online diagnostic data col- centration or even gas void fraction, can
sages to relevant stakeholders to provide lection fall into three categories: safety, time reduce the need for manual sampling and
advanced notice and guidance on how to and cost. The following looks at each one. the associated risks.
remedy the condition. And, ultimately, the
diagnostic data is accepted by regulatory Safety Time
agencies in all industries. Not having to physically check the meter The time regained by not having to physi-
While that list of desired qualities for means personnel are not exposed to cally check every meter is tremendous. It is
the perfect flowmeter was described product in the pipeline. It also means not only time-saving, but also cost-saving.
three years ago, today, the future is much there is no shutdown needed to check the A meter with advanced diagnostics can
closer — with advances in diagnostic meter. During abnormal operation, such provide alerts to problems in the process
All images courtesy of Emerson Automation Solutions

tools and the software running them. as shutdown and startup, safety risks are that a technician can address before process
Advances in technology have allowed greatest, including individual exposure to upsets occur. As a result, regular mainte-
for significant leaps forward in product process fluid. nance can now be scheduled; plant and
development. In particular, many of the There are also inherent dangers to the meter maintenance becomes proactive
chips needed to power diagnostics have process and the product at startup and instead of reactive; and schedule-based
become small enough to fit in a transmit- shutdown separate from the dangers to maintenance is not needed if the diagnostics
ter or wireless diagnostic tool. personnel. With any process disruption, can ensure the meter is working properly.
there is a high probability that product
Diagnostic advances immediately before and after the shut- Cost
Until recently — and this is still the norm down will not meet specifications and Diagnostic costs can add up, particularly
in many plants and oil fields — diagnos- will need to be discarded, resulting in when a meter needs to be removed from
ing a meter meant physically going to product loss, material loss and profit loss the line and sent to a laboratory for test-
the meter and taking readings, resetting — something no plant manager wants. ing and servicing. For large meters, it
certain parameters and then uploading or Many work practices today include fre- can involve cranes or other equipment
manually entering the collected data into a quent manual sampling of the process. to remove the meter.

www.flowcontrolnetwork.com July 2019 | 27

 Having it readily accessible and being able
Statistical trending of meter performance and to effectively use it is the other half.
process offers the tools to optimize productivity Several sensor and meter manufactur-
ers now provide software applications that
while remaining compliant. live on a dashboard — on a smartphone,
tablet, laptop or desktop — and display
In all cases, the process that flows transmitter. The diagnostic indicators all relevant information in an easy-to-read
through that particular meter needs to be should be in the normal state to help format. These apps can be set to alert
stopped, and unless a plant has a spare verify the equipment is working. Checking personnel to process upsets before they
meter, production is stopped until the reca- the configuration for the sensor parameters become critical, offering yet another layer
librated meter is slotted back into place. and making sure they have not changed is of security through advanced diagnostics.
This can be costly; however, the alternative also important. While sensor verification Purpose-built software apps for each
could be worse. An incorrect meter can will vary by manufacturer, it will — in gen- device help connect the dots along
cause any number of problems and can eral terms — check for a change in the the process and offer greater peace of
lead to fines for not meeting regulatory measurement performance. This check mind. Information becomes available at
requirements and environmental standards. can run continuously, on demand or on a a glance, thereby optimizing operations.
To head off these added expenses, a meter periodic basis. Some manufacturers provide
with advanced verification diagnostics that automated meter verification functionality Third-party acceptance
can produce on-site reports accepted by that can be executed without interrupting As mentioned, reports generated by
regulatory agencies can provide significant the process or the measurement and may advanced diagnostic tools can be used
year-over-year cost savings. even provide scheduling functionality to run to meet reporting requirements set by
the verification at an established interval. third-party agencies. This is important
Meter verification because the regulations that govern dif-
Meter verification typically consists of Connecting the dots ferent industries can set stringent rules
checking the health of the sensor and Collecting data is only part of the story. that affect processes. From environmental

28 | July 2019 Flow Control

regulations to safety considerations, it is the contractual and/or legal obligations Motion flow and density measurement
helpful to have a robust process to verify that are part of operations. transmitters and software. Wyatt holds
performance and document the verification. a bachelor’s degree in chemical and
Being able to provide that information Optimizing processes petroleum refining engineering from the
on a regular basis with reports printed Businesses and manufacturers from a Colorado School of Mines with a minor
from data received and collated — without range of industries are constantly seek- in environmental science and engineer-
needing to stop processes to take meters ing the right tools to optimize processes. ing and an MBA from the University of
out of line — means compliance require- Finding the right tools and diagnostics Colorado. She has been with Emerson
ments become easier to meet. to ensure that a plant can run at peak since 2000 in roles including applica-
Statistical trending of meter perfor- efficiency and safety within established tions, new product development, prod-
mance and process offers the tools to parameters can be challenging, especially uct management, gas marketing and
optimize productivity while remaining if a plant is running legacy equipment. chemical industr y marketing. Wyatt
compliant. Tweaks to a system can be Using advanced diagnostic tools that worked for Eastman Chemical Company
tracked through the data gathered. Two- provide real-time insight into the meter in the research and development group
phase flow can be more closely monitored means processes can be fine-tuned as prior to joining Emerson. She is a certi-
and reported. needed without interrupting the process, fied Project Management Professional
Meter verification tools will not always thus helping ensure plant managers meet and a member of the American Gas
replace proving or calibration, but they optimization goals. FC Association (Transmission Measurement
can extend intervals between proving Committee), American Institute of
and calibration because meter health Chemical Engineers, Society of Women
can be checked on-site with data down- Tonya Wyatt is a global senior Engineers and American Chemical
loaded from the meter daily, weekly or product manager at Emerson. Society. Wyatt can be reached at tonya.
monthly. This data will also help meet She is responsible for Micro [email protected].

MULTIPLE INDUSTRIES
THREE BRANDS ONE POWERFUL NETWORK
The Process Flow Network covers innovative solutions for the process
manufacturing industries. Together, the three brands that make up the
network — Processing, Flow Control and Water Technology — reach nearly
150,000 purchase decision influencers.

Deliver your marketing message to a qualified audience of engineering,

plant operations and executive management decision-makers.

Visit ProcessFlowNetwork.com to find out how we can help you build brand
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ProcessFlowNetwork.com

www.flowcontrolnetwork.com July 2019 | 29

 P R O D U C T

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

1 | regulators 2 | flowmeter 3 | level sensor 4 | transmitter

Swagelok’s new low- Blue-White’s DIGI-METER BinMaster’s NCR-84 80 NOSHOK’s 20, 25 and 30
temperature seal options are F-2000 Series electronic, GHz radar sensor is designed Series Intelligent Pressure
designed to maintain a strong digital paddlewheel for measurement in and Level Transmitters
seal in cold climates and flowmeter measures water demanding liquid conditions. meet requirements of the
applications where significant ranges from 0.4 to 8,000 The signal is focused in food and beverage industry,
cooling occurs due to high gpm and features an eight- a narrow beam angle hygienic applications and
pressure drop. Comprised digit LCD readout. Designed for aiming and avoiding harsh ambient conditions.
of low-temperature-resistant to accommodate pipe or obstructions in the tank. It is The transmitters feature a
nitrile material, these wall-mount installations, it offered in threaded, flange design that positions the
regulator components are is field-programmable via and hygienic versions, plus pressure and temperature
ideal for use in environments the front panel touch pad. a plastic antenna option sensors directly behind the
with extensive presence The insertion-style F-2000 for use in low pressure or diaphragm, which minimizes
of hydrocarbons. The seat displays flow rate and total temperature ranges. Data fill fluid and allows the use
seal options will be available flow, and it includes an NPN from the sensor can be sent of a smaller diaphragm. This
immediately on all regulator open collector output for to the BinView application provides active temperature
configurations in the RHPS communication with data or Binventory software for compensation at the point
Series pressure regulators loggers, SCADA systems and live monitoring. of measurement to minimize
product line. other external devices. temperature and position error.

30 | July 2019 Flow Control

 Connect
SOLUTIONS FOR FLUID MOVEMENT, MEASUREMENT & CONTAINMENT

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BC = Back Cover IBC = Inside Back Cover IFC = Inside Front Cover

www.flowcontrolnetwork.com July 2019 | 31

 Featured
content

FlowControlNetwork.com

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32 | July 2019
 subscribe today.
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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

FC_0619_Cover.indd 1 5/20/19 1:09 PM

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 Do you have
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The Emerson logo is a trademark and service mark of Emerson Electric Co. ©2019 Emerson Electric Co.