JULY/AUGUST 2021 | piprocessinstrumentation.

com

PUMP MONITORING
How A Remote Monitoring System
Can Improve AODD Pump Capability

Improving the reliability of safety

instrumented systems with advanced
measurement technologies
Page 20

Case Study: Gore Nitrogen finds

cost-effective flow measurement solution
Page 26

Prevent asset failures using

clues from vibration data
Page 28
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 subscribe today.

P.I. Process Instrumentation serves professionals who

design and operate the instruments that measure the
parameters of systems that control liquids and gases in
industrial processes.

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

piprocessinstrumentation.com/subscribe
 INSIDE
JULY/AUGUST 2021 | VOL 27 | ISSUE 7

COVER SERIES: Pump Monitoring

12 How a remote monitoring system
improves AODD pump capability
Innovative remote diagnostic
performance-monitoring technology
gives real-time visibility into AODD
pump functionality to prevent costly
failures and breakdowns.

17 Exploring options for process

pump automation
Control and monitoring relays provide
enhanced functional and protective
features for process pumps.

FEATURES
12 20 Improve the reliability of safety
instrumented systems with advanced
cover: Courtesy of Wilden measurement technologies
Applying new best practices and technology
selection improves process safety and
keeps personnel out of the field.
DEPARTMENTS
4 Editor’s Note 26 Case Study: Gore Nitrogen finds cost-
effective flow measurement solution
Coriolis flowmeter provides accurate
6 Industry News
readings for non-Newtonian fluids.
8 Application & Quiz Corner
10 Product Focus
31 Advertiser Index
17 28 Prevent asset failures using clues
from vibration data
By collecting vibration data over time,
32 Piprocessinstrumentation.com maintenance teams gain the ability to
compare measurements and failure
mode patterns.

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piprocessinstrumentation.com 20
2 P.I. PROCESS INSTRUMENTATION | JULY/AUGUST 2021
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performance in limited spaces

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 EDITOR'S NOTE
elcome to the July/August
W issue of P.I. Process Instru-
mentation. This issue of P.I.
features a pair of stories on
pump monitoring that we are excited to
share with readers.
In our cover story, Wilden’s Erik Sol-
felt outlines how new remote monitor-
ing technology improves AODD pump
capability. Solfelt writes: “While AODD
pumps have proven to be one of the
simplest to operate, most reliable and
cost-effective, and safest technologies
in a wide range of industrial pumping
applications since their invention in
1955, the simple truth is that at some
point every one of them will cease op-
erating as efficiently as expected or sim-
ply break down. In the past, that meant
nothing more than replacing the old
pump with a new one, but the creation
of an innovative remote monitoring
system for AODD pumps can help their
users wring every last ounce of perfor-
mance out of them, efficiently and safe-
ly, before they need to be retired.
“This digital, cloud-based pump-
monitoring technology uses next-gen-
eration diagnostics to give AODD pump
users the ability to know exactly how
— anytime and from anywhere — their
pumps are operating and if any perfor-
mance-related issues may be looming
on the horizon. The end result is a man-
ufacturing or processing operation that
attains and maintains the highest levels
of efficient AODD pump performance,
reliability and safety.”
Next, Lenny Filipkowski of Automa-
tionDirect explains how control and
monitoring relays provide enhanced
functional and protective features for
process pumps. He writes: “Control and
EDITORIAL ADVISORY BOARD
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 | JULY/AUGUST 2021
monitoring relays are available in many
styles to provide improved pump func-
tionality and to monitor leaks and elec-
trical characteristics …
“Providing the right combination of
relays for pump control applications
improves designs, leading to simpler
operations and maintenance.”
This issue also features articles from
Emerson and Fluke, along with a case
study from Endress+Hauser. I hope
you find the content in this issue both
interesting and informative. As always,
thank you for reading.
The Measurement of Process Parameters
Coming soon: 2021 Innovation
Awards winners
As of this writing, we are in the final
days of the voting period for our 2021
Innovation Awards, which recognize
the latest innovations and technology
breakthroughs in process instrumenta-
tion over the course of the past year. Be
sure to check out the October issue of
P.I. Process Instrumentation to read about
this year’s winner and honorable mentions.
Thank you to the companies that
nominated their products and tech-
nologies for consideration this year. And
thank you to all of you who took the time
to vote this year. It is greatly appreciated.
Sincerely,
EDITOR IN CHIEF
josborne@endeavorb2b.com
The Measurement of Process Parameters
CONTENT
Publisher Jim Semple
jsemple@endeavorb2b.com
Editorial Director Angela Godwin
agodwin@endeavorb2b.com
Editor in Chief Jesse Osborne
josborne@endeavorb2b.com
Managing Editor Molly Rogers
mrogers@endeavorbusinessmedia.com
Columnist David W. Spitzer
Art Director Ryan Carlson
rcarlson@endeavorbusinessmedia.com
Production Manager Shirley Gamboa
sgamboa@endeavorbusinessmedia.com
ADVERTISING
District Manager Jay Haas
281-980-5831 | jhaas@endeavorbusinessmedia.com
Account Manager Lisa Williman
518-322-6691 | lwilliman@endeavorbusinessmedia.com
MARKETING
Marketing Manager Sarah De Vos
Digital Operations Manager Mary Beth Romano
Digital Product Director Nick Phillips
Audience Development Manager Anna Hicks
CORPORATE
CEO Chris Ferrell
CRO/CMO June Griffin
CFO William Nurthen
COO Patrick Rains
Chief Administrative and Legal Officer Tracy Kane
EVP/Industrial Group Mike C. Christian
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The Measurement of Process Parameters

 INDUSTRY NEWS
JULY/A UGUST 2021 THE LATEST NEWS & EVENTS FROM AROUND THE INDUSTRY piprocessinstrumentation.com

COMPANY NEWS
Brooks Instrument celebrates 75 years of
innovation in fluid measurement and control
Brooks Instrument is celebrating its 75th year
providing high-precision fluid measurement
and control instrumentation. To help com-
memorate the milestone, the company devel-
oped a special 75th anniversary webpage at
experience.brooksinstrument.com/75-years.

Courtesy of Sensirion
A world leader in advanced flow, pressure
and vapor delivery solutions, the company
serves customers across many industries,
including semiconductor manufacturing,
pharmaceutical, biopharmaceuticals, fiber
optics, thin film manufacturing, solar cells,
LED, alternative energy, oil and gas, chemi-
GC analyzers from Qmicro power the first process gas cal and petrochemical. Headquartered in
Hatfield, Pennsylvania, the company has a
analyzer installed directly in a natural gas pipeline diverse employee base, working in manufac-
turing, sales and service locations through-
Qmicro by Sensirion, the innovative OEM provider of miniaturized gas chromatograph out the Americas, Europe and Asia.
analyzers, now supports MeterQ Solutions GmbH with its microGC technology. MeterQ,
a solution provider in the natural gas industry, recently completed the world’s first VorTek Instruments expands temperature
installation of a process gas chromatograph directly in a natural gas pipeline. This and pressure capabilities for multiple
achievement was realized due to Qmicro’s microGC technology, which is at the heart product lines
of the MeterQ solution. VorTek Instruments announced expanded
MeterQ successfully installed the first ever process gas chromatograph (PGC) in temperature and pressure capabilities for
a pipeline in a compressor station of one of its project partners near the German/ multiple product lines. The following prod-
Dutch border in northern Germany. The PGC measures 13 components of natural uct lines are now available with ANSI 900#
gas including C6+, hydrogen, oxygen and nitrogen, with each separated by only one flanged process connections: Pro-V Inser-
carrier gas (helium) in only 45 seconds. Due to the innovative microGC technology, tion Vortex Flow Meter (Model M23); Pro-V
the system could be designed without requiring a bypass channel. This means that Inline Vortex Flow Meter (Model M24); Turbo
natural gas emissions to the atmosphere are reduced by over approximately 95% Pro Insertion Turbine Flow Meter (Model
compared to conventional systems. Pro-T); and VorCone Steam Quality & Flow
In addition to the ability to measure a wide range of gases at an ultra-fast mea- Meter (Model MVC). This expansion of ca-
surement time, Qmicro’s microGC analyzers offer long-term autonomy due to their pabilities will allow these products to oper-
low carrier gas consumption and automated re-calibration. The ultra-compact form ate in severe-service applications, such as
and explosion-proof housing mean they can be installed at virtually any location. In superheated steam, compressed gases and
addition, the innovative cartridge system ensures that the replacement of consum- upstream oilfield applications. VorTek Instru-
ables is fast and easy. All of these aspects make Qmicro products an ideal solution ment’s web-based flow meter sizing pro-
for applications where natural gas properties need to be analyzed, such as custody gram can be used to help determine which
transfer, bio-methane injection and hydrogen blend stations. process connections may be best suited for
a specific application.

6 P.I. PROCESS INSTRUMENTATION | JULY/AUGUST 2021

Gardner Denver’s new V3 valve improves
performance in frac operations
Gardner Denver High Pressure Solutions (GD)
announced it has proven in field trials that
its new V3 valve significantly increases per-
formance hours in high pressure hydraulic
fracturing operations. GD Redline valves and
seats are designed for maximum performance
and reliability with the full-open, bonded de-
sign, providing optimal flow efficiency and
maximum sealing. In line with GD’s commit-
ment to continuous innovation, the V3 valve
has undergone a complete redesign to im-
prove metallurgy and heat treatment, resulting
in enhanced wear resistance and strength.
During field trials in the Eagle Ford, Perm-
ian and Marcellus shale plays, increased
performance of up to 46% over the leading
competitor was observed. In the Permian ba-
sin, performance of the V2 and V3 could be
compared, with an increase in performance
of 81% witnessed.
SVF Flow Controls president Wayne Ulanski
announces retirement
SVF Flow Controls announced Wayne Ulanski
is retiring as president of the valve and automa-
tion company. Ulanski joined the company in
1995 and served in a variety of roles within
engineering, sales, marketing and management.
“Wayne has continued the SVF Flow Con-
trols legacy: a commitment to excellence, in-
tegrity and ethics and recognizing that team-
work is a key component of our success,”
said Jack McDonald, president of parent
company Matco-Norca. “We will continue
this legacy by applying these same values to
the work we do every day at SVF Flow Con-
trols. On behalf of the company, I would like
to wish Wayne and his entire family much
health and happiness.”
Endress+Hauser expands partnership
with Field Instruments and Controls
Endress+Hauser announced an expansion of
its partnership with sales representative Field
Instruments and Controls in the Pacific North-
west region. Effective July 1, 2021, Field Instru-
ments and Controls will be Endress+Hauser’s
Authorized Service Provider for Oregon, Wash-
ington and the Idaho panhandle. Field Instru-
ments and Controls is based out of Woodland,
Washington, and has been an Endress+Hauser
sales representative in the Pacific Northwest for
the past 12 years. The company was estab-
lished in 1987 with the main goal of providing
the finest instrumentation and controls techni-
cal sales and support to its customers.
“Exceeding our customers’ expectations
is our primary goal,” said Nick Sullivan, sales
manager, Field Instruments and Controls. “Over
the years, it has become clear that our organi-
zation needed to increase the level of support
in our service areas, including calibration and
start-up. We must focus and continue to pro-
vide exceptional and unique Field Instruments
and Controls service to our customers.”
ValvTechnologies and Severn form strategic
partnership in the severe-service valve market
ValvTechnologies and Severn Glocon have
reached a partnership agreement that
will see collaboration between two of the
world’s leading engineering and manufac-
turing companies specializing in innovative,
high-end severe-service valves. Subject to
regulatory approval in the U.S., the partner-
ship will combine the brands’ distinctive and
complementary capabilities to extend the
global reach, product offerings and customer
service of both companies. Backed by Blue-
water, the international energy private equity
firm, the collaboration will see many customer
and sales synergies that will offer significant
added value to the marketplace.
Headquartered in the U.K. and with prem-
ises worldwide, notably manufacturing fa-
cilities in India, Severn specializes in control,
choke and small-bore subsea valves for the
energy industry. Headquartered in Houston,
Texas, ValvTechnologies also has premises
worldwide, and it is a global leader in the
design and manufacture of metal-seated,
zero-leakage, severe-service valve solutions
for the harshest applications.
ABB’s automation and control systems to
strengthen technical platform for salt-based
energy storage company
ABB has signed a cooperation agreement with
Sweden-based energy storage company SaltX
Technology to enable the development of a
stable and scalable control system for EnerStore,
a large storage development for the com-
mercialization of nanocoated salt technology
innovations. SaltX’s technology allows salt
to store power with a high energy density in
a bulk material, which means it could scale to
hundreds of megawatt (MW) hours, becom-
ing a circular and sustainable energy storage
solution for suppliers and customers across
industries such as pulp and paper, metals and
manufacturing. The innovative nanocoating,
developed by SaltX over 15 years, makes it
possible for systems to have a long lifetime, en-
abling customers to energize the storage when
the electricity price is low and use the stored
energy when prices are high, fulfilling their mis-
sion to help society shift to sustainable energy.
ABB’s scope of supply for the initial pilot
includes automation and control systems, mo-
tors and drives systems, process instrumenta-
tion and smart electrification, with potential to
scale up the solution for industry customers.
ABB’s established experience in scalable con-
trol systems will help ensure that the technical
platform at EnerStore is optimized for the an-
ticipated high demand in the future.
Difference/Sum LVDT Signal Conditioner
improves sensor performance over large
temperature variations
NewTek Sensor Solutions introduces a new
series of difference/sum LVDT Signal Condi-
tioners that improve a sensor’s performance
during large temperature variation. By measur-
ing the difference of the output over the sum
(S1-S2)/(S1+S2), the NTC-6000-DS Quick-
Cal LVDT Signal Conditioner compensates for
changes in resistance in copper windings due
to temperature fluctuations. As a result, the
Ratiometric Signal Conditioner is ideal for use
with AC-LVDTs in harsh environments with ex-
treme temperature swings such as aerospace
test stands, packaging equipment, factory au-
tomation, turbine control systems and steam
valve positioning.
The NTC-6000-DS LVDT Signal Conditioner
is compatible with standard and constant sum
AC LVDTS and RVDTs including NewTek’s
NT-HT-1000 High Temperature LVDT Position
Sensor Series designed for difference/sum
measurement. These smart signal condition-
ers are RoHS compliant and CE-certified for
use in Europe.
Send news and events for consideration to
Molly Rogers at mrogers@endeavorbusinessmedia.com.
JULY/AUGUST 2021 | piprocessinstrumentation.com 7
 APPLICATION CORNER
By David W. Spitzer
Principal,
Spitzer and Boyes, LLC
David W. Spitzer is a principal
at Spitzer and Boyes, LLC,
which offers engineering,
focused market research,
writing/editing white papers,
strategic marketing consult-
ing, distribution consulting,
seminars and expert witness
services for manufacturing
and automation companies.
Spitzer has written more than
400 technical articles and 10
books about flow measure-
ment, instrumentation and
process control. He can be
reached at 845-623-1830 or
via spitzerandboyes.com.
8 P.I. PROCESS INSTRUMENTATION | JULY/AUGUST 2021
A problem of high
sewage flow
revious columns described the sew-
P
age collection systems for two adja-
cent sewage districts and how the
costs associated with operating the
sewage treatment plant were allocated and billed.
As a side note to previous discussion, the bill-
ing agreement terms provided ample incentive for
the first sewage district to maintain a tight sewage
system with low inflow and infiltration (I&I).
On one occasion, the first district noticed an
unusually high sewage flow through one of the
four flowmeters during the wee hours of the
night. Underground sewage pipes were tem-
porarily blocked off in an attempt to locate the
source of what seemed to be excess sewage.
After a few nights, testing pinpointed the
source to be coming from one sewage pipe that
served a handful of residential houses. Inter-
nal examination of the houses revealed that so
much groundwater was leaking into the base-
ment of one of the houses that its sump pump
was pumping the groundwater to its sewage
pipe almost continuously to prevent the house
from flooding.
One of the workers mentioned that it seemed
like a river was flowing through the basement di-
rectly to the sewage system. This resulted in an
additional sewage expense of approximately $20
per day (approximately $7,000 per year) plus ad-
ditional surcharge billing on wet weather days.
The homeowner was given an offer that could
not be refused: fix the problem within a few days
or pay the difference in the sewage bill.
Read more next issue about the high cost
of surcharges.
 Which of the following orientations can be used to install a Coriolis mass flowmeter
to measure the mass flow of a gas 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 gas service must be tubes can accumulate liquid in the upstream
completely full of gas to measure accurately. The U- (lower) portion of the tubes when mounted in a

51311626 / Background ©Patboon2521 | Dreamstime.com

tube down orientation (Answer A) could accumulate
liquid and should not be used for gas applications.
The inverted U-tube orientation (Answer B) and hor-
izontal orientation (Answer C) would entail modifica-
tion of the upstream and downstream piping. The flag
position (Answer D) would typically be most practical.
Additional complicating factors
flag position (Answer D), so the upstream and
downstream piping should be modified to mount
the flowmeter with its delta-shaped tubes inverted
(Answer B) or horizontal (Answer C).
Similarly, a single-path self-filling and self-
draining Coriolis mass flowmeter that forms
a loop, jumps up (sideways if mounted in flag
position) and then forms another loop must be

QUIZ Not all Coriolis mass flowmeters have U-tube ge-

ometry, and some of these geometries can allow
liquid to accumulate in the flowmeter. For exam-
CORNER ple, a Coriolis mass flowmeter with delta-shaped
installed in the horizontal plane (Answer C) to
remove all liquid from the system because any
other orientation can allow liquid to accumulate
in the flowmeter.
 P R O D U C T

FOCUS
Send products for consideration in this section
to mrogers@endeavorbusinessmedia.com

differential pressure transmitters

AutomationDirect’s ProSense DPTW series differential pressure transmitters are precision
engineered for accurate differential or gauge pressure measurement of a wide variety of
liquids, gases and steam applied to both pressure sensing ports. The ProSense DPTW
series is up to 8 times smaller than a conventional style DP transmitter and is ideal for
industrial, commercial and OEM process measurement applications, including differential,
positive or negative pressures. The DPTW series can also be used to measure hydrostatic
liquid level in pressurized or open tanks and flow measurement using primary differential
pressure flow elements such as an annular pitot tube, orifice plate or venturi tube. Seven
models are available with various measuring ranges of up to 400 inches of water column,
each offering 4-20 mA outputs, 12-32 VDC operating voltage, and ¼-inch female NPT
process connection. Backed with a three-year warranty, the ProSense DPTW series
differential pressure transmitters have a rugged NEMA 4X rating.

www.automationdirect.com

analog pressure gauges

AnTech Ltd. launched Metior, a Downhole Analog Pressure

flowmeters
Endress+Hauser introduces a new line of flowmeters, the
Proline 10, with a stronger focus on simplicity and user-
friendliness. Every device is tested on accredited and traceable
calibration rigs per ISO/IEC 17025. Proline 10 flowmeters cover
a range of basic applications. Proline Promag electromagnetic
flowmeters are suited for measuring the flows of conductive
liquids, as well as for volume measurement of water and
corrosive liquids (Promag W/H/D 10), and chemically aggressive
fluids (Promag P 10). Promass K 10 Coriolis flowmeters measure
the mass flow of liquids and gases in utilities. In the chemical
industry, Promass K 10 is used to measure the mass flow of
liquids such as acids, alkalis, cleaning agents and solvents, oils
and alcohols, as well as liquid hydrocarbons. In the food and
beverage industry, the device measures the admixture quantity
of animal fats or carbon dioxide during beverage carbonization.
Gauge, targeted at the well dewatering market. The
development team focused on ease of installation, durability
and corrosion resistance. The Metior gauge has been designed
to withstand the shock and vibration that can be caused by
downhole pumps installed nearby. It uses silicon-on-sapphire
technology for long-term stability and is currently undergoing
testing in accordance with AWES (Advanced Well Equipment
Standards) Recommended Practice for Qualification of Downhole
Sensors. Corrosion resistance has been addressed through the
selection of suitable corrosion resistant alloys for all wetted parts.
Corrosion protection extends to the exposed tubing encapsulated
cable with the use of a protective sleeve, which has the added
benefit of increasing shock and vibration resistance.
www.antech.co.uk

www.us.endress.com

10 P.I. PROCESS INSTRUMENTATION | JULY/AUGUST 2021

 FLOW AND PRESSURE MEASUREMENT

gear meters
AW-Lake Process Flow Measurement’s Next-Generation Gear
Meter Series offers greater efficiencies in operation with tighter
tolerances, higher resolutions, higher standard pressure ratings
(6000 psi), improved accuracy, wider turndowns (100:1) and
a new low-viscosity series. Designed with high-performance
materials, the Next-Generation Gear Meters offer high chemical
resistance to operate safely in abrasive or filled fluids while
providing a long service life of more than 30 years in the field,
+0.1% repeatability and +0.5% standard accuracy. These
positive displacement gear meters work in bidirectional
flow applications and are unaffected by changing viscosities.
The Gear Meters offer multiple output options including
pulse, analog or Modbus to deliver data in required formats
for PLCs, PCs and remote displays. PC-based applications
streamline installation, configuration and troubleshooting.
low-flow controller
Intek Inc.’s Rheotherm Model 210 Low-Flow Controller
is the newest addition in its line of flow instruments.
The Low-Flow Controller consists of a standard Rheotherm
Model 210 Flow Meter with an integrated proportional control
valve. The Flow Controller can measure and control the flow
rate of either liquids or gases inline by continuously adjusting
the valve to maintain the measured flow to a user-determined
set point. The flow rate set point is set either by adjusting an
onboard potentiometer or via an external 0-5V analog input.
The Low-Flow Controller utilizes the thermal mass principle
for highly accurate and repeatable measurement of the
fluid through an unobstructed flow path through the sensor.
The instrument includes temperature compensation and
accounts for pressure variations.
www.intekflow.com

www.aw-lake.com

pressure gauge/transmitter
KOBOLD released the latest version of its electronic digital pressure gauge, model MAN-SC for
battery powered, and model MAN-LC for 24 Vdc power with IO-link. KOBOLD developed the new
MAN-SC/LC instruments to produce a high-quality digital pressure gauge that satisfies traditional user
applications and reaches out to new industry sectors. It features a new alpha-numeric 14-segment
reflective LC-display screen. The electronic screen module can now be rotated in 90-degree
increments. The gauge head position can now be radially adjusted after installation for perfect
positioning. Access to the screen options is now by capacitive touchpads. An impressive range of
measuring units are now accessible for selection from the programming menu. The range of process
connection threads has also been substantially increased and now includes metric threads.

www.koboldusa.com

JULY/AUGUST 2021 | piprocessinstrumentation.com 11

 PUMP MONITORING
COVER STORY
HOW A REMOTE MONITORING SYSTEM
improves AODD pump capability
Innovative remote diagnostic performance-monitoring technology gives real-time
visibility into AODD pump functionality to prevent costly failures and breakdowns.
By Erik Solfelt, Wilden
ince its invention 65 years
S ago, air-operated double-
diaphragm (AODD) pump
technology has been a loyal
soldier in the constant battle to deliver
reliable, durable, safe, cost-effective
and efficient performance in utilitarian
pumping applications, from dewatering
mines to producing pharmaceuticals.
The plug-and-play reliability of AODD
pumps has helped them earn a “set
it and forget it” reputation among its
many devoted users.
That capability has also prompted
some AODD pump users to term the ma-
chine a “run to failure” piece of machinery.
This means that after it is initially turned
on, since it requires very little mainte-
nance, it just runs and runs until it cannot
run anymore; at which point, it is simply
replaced with a new model, starting the
whole process over again.
Attitudes have evolved regarding
pump monitoring over the past six de-
cades, however. Specifically, the “run
to failure” mindset among industrial
pump users has generally become a
thing of the past for a number of nota-
ble reasons: a former understanding of
the true cost of equipment downtime;
higher pump purchase costs combined
with tightening capital-investment
budgets; the health and safety risks that
malfunctioning pumps can pose to peo-
ple and the environment; rising main-
tenance costs for labor and time; and
regulatory agencies that are becoming
12 P.I. PROCESS INSTRUMENTATION | JULY/AUGUST 2021
“AODD pumps that operate efficiently will not only last longer but will
also require less air to run, which makes them more cost-effective
while reliably delivering the flow rates that the user requires.”
more diligent in demanding that leaks
of hazardous and dangerous products
occur less often.
All of these factors prompted the de-
velopers of many types of pump tech-
nologies to invent ways that their
machines could be monitored without
the need of a technician to actually be
on-hand to visually gauge and record
the pump’s performance levels. With
that, significant breakthroughs have
been made in cloud-based remote
monitoring technology for a number
of popular pump technologies, espe-
cially those that are more complicated
to operate and have correspondingly
higher purchase, maintenance and
repair costs, which makes it less cost-
effective to simply replace them when a
breakdown occurs.
A new digital age
One technology that has not been in-
cluded in this trend toward taking advan-
tage in the advances in remote monitoring
capabilities is the AODD pump. Again,
this has mainly been due to the factors
listed above: low purchase cost, a design
with few moving parts that can wear or
fail, simple and reliable operation, and
easy replacement when failures do occur.
However, referencing again some
of the aforementioned factors, with
capital budgets getting squeezed, op-
timizing performance and service life
becomes more important. It is also im-
portant to note that pumps that oper-
ate efficiently will not only last longer
but will also — in the case of AODD
pumps — require less air to run, which
makes them more cost-effective while
reliably delivering the flow rates that
the user requires.
So, it was a landmark day in the
long, cherished history of the AODD
pump when, in 2020, the technology’s
first remote diagnostic performance-
monitoring system was introduced to
the market. Specifically, this technol-
ogy enables the quick identification of
operational inefficiencies within the
pump’s performance sooner and more
reliably, creating real-time operational
visibility and significant cost savings
for the operator through continuous
24/7/365 cloud connectivity. This new
diagnostic AODD pump-monitoring
technology also possesses the ability
to communicate directly with the user,
while compiling expansive amounts of
operational data that can be used to
accurately predict when a breakdown
might occur or preventative mainte- • Data Storage: The pump’s second- A team effort
nance might be required. by-second operational data is sent to All of these components work in har-
This remote-monitoring technology for the cloud, where it is stored and made mony to provide a full picture of how
AODD pumps has five basic components: available for review by the operator. the pump is operating: the Monitoring
• Monitoring Device: This is installed • User Interface: This enables the Device compiles stroke rate and stroke
on the pump’s Air Distribution Sys- pump’s gathered operational infor- count information to monitor perfor-
tem (ADS) where it records, collates mation to be viewed by the user mance, while the Leak Detection Sen-
and compiles the unit’s stroke rate anywhere in the world, providing in- sor monitors for leak-detection warn-
and stroke count information. sight into performance history that ings, if necessary, all in real time. At the
• Leak-Detection Sensor: This is in- can help the user predict when a same time, the Gateway Node encrypts
stalled between the pump’s ADS and failure may occur or if and when any the performance data and securely
muffler where it monitors whether type of preventative maintenance
the pump has begun leaking, usu- may be necessary.
ally around the diaphragms, and
sends an alert to the user if leakage
has begun.
• Gateway Node: This is precon-
figured for the specific pump and
stores the information gathered by
the Monitoring Device and Leak
Detection Sensor; up to 10 intercon-
nected pumps can be synced to the
Gateway Device as long as they are
located within 150 feet of each other.

 Figure 1: Because of their simple design and

method of operation, as well as rugged and reliable
performance and oftentimes predictable service
life, AODD pumps have been an afterthought in the
development of advanced diagnostic performance-
monitoring systems. That has changed, however,
with the invention of a cloud-based monitoring
system that allows users of AODD pumps to more
accurately track and review performance levels,
leading to optimized efficiency, maintenance
schedules and operating costs.
All images courtesy of Wilden
transmits it to the cloud for analysis and
storage via a global cellular-data service.
All of this critical performance data is
readily accessible at the User Interface
via either a mobile smartphone app or
a web-based computer dashboard —
again, from anywhere in the world.
Let’s dig a little deeper into the capa-
bilities of some of these components:
• The ability of the Monitoring De-
vice to observe the pump’s stroke
rate enables it to detect when any
abnormal pumping conditions may
arise; for example, when a pump
that typically operates at a rate of
70-80 strokes per minute begins
producing 115 strokes per minute.
When this happens, the operator is
alerted, letting him or her know that  Figure 2: Two key components of the new cloud-based AODD pump monitoring system are the Leak
Detection Sensor, left, and Monitoring Device, both of which install on the pump and compile operational
either something has changed in the information that the user can refer to in order to assess the pump's level of performance and whether
facility’s system that needs to be ad- maintenance or replacement may soon be required.
dressed or something has changed
in the pump’s operation that may
require review or repair. occurred, a warning threshold of, say, which allows the user to take steps to
• By compiling stroke counts, the 250,000 strokes can be created so the ensure it does not.
Monitoring Device collects detailed user will know to check on the pump • While AODD pumps are seal-less,
information on how long the pump at that time. This capability provides they will leak when a diaphragm
has operated and how much longer it unprecedented information to the rupture occurs, which most often
might be expected to continue to op- user that can be used to establish a results in unwanted and poten-
erate effectively. For instance, if it is laser-targeted preventative mainte- tially dangerous product discharge
known that a previous pump used in nance schedule that can help predict through the pump’s muffler. To com-
the same application lasted 275,000 when a diaphragm rupture or other bat that unwanted occurrence, the
strokes before a diaphragm rupture operational hiccup might occur, Leak Detection Sensor is equipped

 Figure 3: The new AODD pump-monitoring system can connect up to 10 pumps and provides the user with a wide array of real-time and historical
performance-related data, all of which is stored securely and available for review at any time from anywhere in the world.

14 P.I. PROCESS INSTRUMENTATION | JULY/AUGUST 2021

 with a float switch that will trigger
an alert that is sent to the user as
soon as the product leaks into the
unit’s leak-detection housing. This
early-warning system enables the
user to address the problem im-
mediately, eliminating the chance
that a pump can leak unnoticed for
hours or even days; all of which will
result in costly and dangerous spills.
• The User Interface gives real-time
fingertip access to all of the pump’s
operational data, along with any
warnings that may require immedi-
ate attention. The User Interface is
fully customizable so each pump’s
stroke rate and stroke count param-
eters can be set individually. The
interface can also be configured so
that multiple team members have
access to the same information,
all operating and maintenance his-
tories can be reviewed whenever
“The Leak Detection Sensor is equipped with a float switch that will
trigger an alert that is sent to the user as soon as the product leaks
into the unit’s leak-detection housing.”
needed, SMS and email alerts can
be customized, and color-coded in-
dicators provide an at-a-glance in-
sight into real-time operational and
alert status.
Assessing the true benefits
When considering the simple and re-
liable performance of AODD pumps,
it does not seem like remote perfor-
mance monitoring will make that much
of a difference. But how many opera-
tions rely on just one pump? In fact, it
is far more likely that a fleet upward of
50 AODD pumps may be used even in
just a typical operation. Many of these
pumps also may run for days without
observation or be located in a faraway
corner or hard-to-reach location within
the facility.
In a case such as this, a facility that
produces 5 million gallons of paint
annually can have a roster of AODD
pumps that are situated in a remote
corner of the facility. A single pump
failure can result in the leakage of
5,000 gallons of paint onto the floor. If
this were to occur, taken together the
cost of lost product ($16,000), cleanup
($4,000), labor ($3,000), equipment re-
placement ($1,000) and Hazmat reme-
diation and disposal ($5,000) can mean
a total loss to the producer of nearly
$30,000. The installation of a remote
JULY/AUGUST 2021 | piprocessinstrumentation.com 15
monitoring system can prevent this
spill incident from occurring through
notification to the user that a potential
failure or breakdown was possible.
R e m o t e m o n i t o r i n g of A O D D
pumps can also prevent the replace-
ment of a pump or its components
while they still have some service life
left in them. This premature replace-
ment usually occurs when the user
reviews performance records and sees
that the AODD pumps in use, for in-
stance, have historically needed to
have their diaphragms replaced every
six months. However, an AODD pump
outfitted with a remote monitoring
system may show that its actual op-
erational diaphragm life is closer to
12 months. For a ceramics manufac-
turer that deploys 100 AODD pumps,
this can reduce parts and labor costs
by 50% per year, or in this example, as
much as $50,000.
2108PI_WildenPump 1
16 P.I. PROCESS INSTRUMENTATION | JULY/AUGUST 2021
Conclusion
While AODD pumps have proven to
be one of the simplest to operate, most
reliable and cost-effective, and safest
technologies in a wide range of indus-
trial pumping applications since their
invention in 1955, the simple truth is
that at some point every one of them
will cease operating as efficiently as
expected or simply break down. In the
past, that meant nothing more than
replacing the old pump with a new
one, but the creation of an innovative
remote monitoring system for AODD
pumps can help their users wring every
last ounce of performance out of them,
efficiently and safely, before they need
to be retired.
This digital, cloud-based pump-mon-
itoring technology uses next-generation
diagnostics to give AODD pump users
the ability to know exactly how — any-
time and from anywhere — their pumps
WE DIDN’T INVENT THE
PREVENTATIVE MAINTENANCE PLAN.
WE JUST PERFECTED IT.
are operating and if any performance-
related issues may be looming on the
horizon. The end result is a manufactur-
ing or processing operation that attains
and maintains the highest levels of ef-
ficient AODD pump performance, reli-
ability and safety.
Erik Solfelt is the Diaphragm
Pump product manager for
Wilden — headquartered in
California and a leading man-
ufacturer of air-operated double-diaphragm
(AODD) pumps. He can be reached at (909)
422-1741 or Erik.Solfelt@psgdover.com.
Wilden is a product brand of PSG, a Dover
company. P SG is comprised of sev-
eral leading pump companies, including
Abaque, All-Flo, Almatec, Blackmer, Ebsray,
EnviroGear, Griswold, Mouvex, Neptune,
Quattroflow, RedScrew and Wilden. Find
more information at wildenpump.com and
psgdover.com.
7/15/21 10:31 AM

Exploring options for process pump automation
Control and monitoring relays provide enhanced functional
and protective features for process pumps.
By Lenny Filipkowski, AutomationDirect
rocess control applications
P are progressively relying on
digital automation to pro-
vide optimized operation,
better diagnostics and enhanced data.
However, sometimes there are very
good reasons to integrate just the right
amount of hardwired controls with these
digital platforms to provide the best
functionality. This can be the case for
all types of process pump automation,
where a variety of control and protective
relays are available to provide complete
hardwired automation, or close integra-
tion with other digital controls.
Tending to the workhorses
Process pumps are workhorses of many
types of processing and manufacturing
industries (Figure 1). They come in many
physical configurations and capacities,
and they may be operated at fixed or
variable speeds.
Some pumps are specialized for han-
dling product in hazardous petrochemi-
cal locations or hygienic life sciences
applications. Others are much more of a
commodity and simply pump utility or
sump water.
It is common to drive process pumps
with electrical motors and three-phase
power. Here are some typical functional
and protective features needed for in-
dustrial process pumps:
• Alternating operation
• Seal failure monitoring
• Electrical monitoring
• Intrinsically safe signaling
PUMP MONITORING
Figure 1: Automatically
controlled pumps are a
fundamental type of equipment
used in many processing and
manufacturing industries, and
they must be integrated with
certain functional and protective
control and monitoring features.
All images courtesy of
AutomationDirect
For smaller and simpler hardwired sys-
tems, it is common to use specialized
electrical relays to perform some or
all of these functions. Even for larger
systems or those employing program-
mable logic controllers (PLCs) or other
digital controllers, there are many rea-
sons to incorporate mission-specific
relays for these purposes.
Alternating relays
Many processes employ two pumps for
redundancy — only one pump needs to
run at any given time, and it does not
matter which one it is, but it is impor-
tant that a second pump be available to
operate if the first one fails. This is typi-
cal functionality for pumping liquids
out of tanks or sumps on an intermittent
JULY/AUGUST 2021 | piprocessinstrumentation.com 17
  Figure 2: Phase-monitoring relays, seal failure relays and alternating relays from the AutomationDirect ProSense series provide
many options for users to add local protective and diagnostic features to process pumps and to interface with higher-level automation.
basis. However, it usually is not desir-
able to only run one pump as needed
while keeping the other in reserve.
An alternating relay is a basic device
that takes a signal start command from
any hardwired or digital logic and al-
ternately starts one load or the other,
helping to equalize runtime between
the pumps. The relay may also have in-
dicating lights and a switch so users can
override operation to only one of the
pumps, making it easier for them to ser-
vice the second pump.
Seal failure relays
Some types of pumps are submersed
into a sump instead of being installed
on the outside of a vessel. While this is a
convenient installation method and can
serve to cool the pumping equipment, it
also makes the electrical motor suscep-
tible to water intrusion from leaks.
A seal failure relay works with stan-
dard resistive shaft seal leak sensors,
and it is easily adjustable to match the
sensor type. When the monitored sen-
sor detects water, the relay actuates to
indicate the fault. Designers can simply
trigger an alarm based on this, or they
can perform more elaborate operations,
such as stopping the faulted pump and
starting another.
Phase-monitoring relays
Three-phase electrical motors used for
pump service can experience several
types of faults. If a single upstream fuse
blows, or if one of the motor windings
fails, the motor may continue to operate
18 P.I. PROCESS INSTRUMENTATION | JULY/AUGUST 2021
in a single-phase mode, which is not automation located outside the hazard-
desirable. Other electrical problems ous area (Figure 3).
include phase reversal, phase unbal-
ance, undervoltage and overvoltage. Pump application benefits
Each of these is a sign of electrical sys- Pump control and monitoring relays are
tem issues, which will likely result in convenient for many reasons. Among
undesirable operation, often leading to the most important features they pro-
larger problems. vide is a local method for maintenance
A basic phase-monitoring relay may personal to check the functional status
be used to detect some of these issues, of the equipment and perform any trou-
while more advanced microprocessor- bleshooting necessary.
based versions can detect all these issues These types of relays minimize down-
(Figure 2). As with seal failure relays, time by equalizing equipment runtime
it is good practice to incorporate or by providing early detection of any
phase-monitoring relays with auto- potential problems. This early warning
mation system designs to alarm and is critical so users can respond before
usually stop equipment experiencing
electrical problems.
Intrinsically safe signaling
Any time electrically driven pumps are
located in hazardous locations where
explosive vapors may be present, de-
signers need to make provisions to
comply with the National Electrical
Code. Note that hazardous locations
are not always exactly where explosive
liquids are being pumped; they can
also be in low-lying or contained areas
where vapors might accumulate.
One approach is to use single- or
multi-channel intrinsically safe relays
to permit signaling but act as an energy
barrier, limiting the amount of voltage
and current available in the hazardous
area and protecting against ignition.
Intrinsically safe relays allow electrical  Figure 3: Intrinsically safe relays, such as this
Macromatic model offered by AutomationDirect,
contacts, switches or sensors in hazard- may be needed to interface monitoring and control
ous areas to be monitored safely by functions with equipment located in hazardous areas.
operational issues escalate. Or, control pump control applications improves more than 28 years of experience working
systems can use the fault information designs, leading to simpler operations with industrial equipment and controls for the
to make intelligent operating decisions and maintenance. manufacturing, steel, water/wastewater treat-
and keep processes running. ment, pulp and paper, non-woven industry
Digital phase monitor relays, in par- Lenny Filipkowski is a product and conveying industries. Filipkowski lever-
ticular, provide important benefits be- manager at AutomationDirect. ages this experience to connect Automation-
cause they can detect so many possible He began his career as an Direct customers with the right products and
electrical issues; some of which may electrical engineer and has solutions for their applications.
not cause immediate shutdowns but
can clearly indicate a larger problem
may be developing. These relays will
provide a single trouble signal to the
supervisory control system, while us-
ing pulsing indicator lights to locally
identify the type of trouble.
For original equipment manufactur-
ers (OEMs), pump relays provide a con-
venient way for them to standardize the
designs of their control panels. Further-
more, when these OEMs find it neces-
sary to offer various options or makes/
models of automation systems for their
pump equipment, these control and
monitoring relays can provide consis-
tency and simplify the interface to any
type of automation system.
For instance, an OEM can offer their
pumps with standard interface control
panels preconfigured with the appropri-
ate relays. End users can apply whatever
supervisory controls make sense for the
process and their operating standards.
Maintenance personnel and OEM ser-
vice technicians will all be familiar with
the common relay designs when they
are servicing the pumps, regardless of
the automation platform.

Enhanced process pump protection

Control and monitoring relays are
available in many styles to provide
improved pump functionality and to
monitor leaks and electrical charac-
teristics. These relays are an economical
way to provide a consistent interface
with electrically driven pumps, which
in turn can be operated by any type
of hardwired or digital controls. In
addition, these relays are a straight-
forward way to provide local indica-
tion and troubleshooting features for Ph: 209.943.6088
maintenance personnel. Providing www.procoproducts.com Toll-Free: 800.344.3246
the right combination of relays for

2108PI_ProcoProducts 1
JULY/AUGUST 2021 | piprocessinstrumentation.com 19
7/19/21 1:47 PM
 MEASUREMENT
Improve the reliability
of safety instrumented
systems with advanced
measurement technologies
Applying new best practices and technology
selection improves process safety and keeps
personnel out of the field.
By Meha Jha and Julie Valentine, Emerson
ccording to Reuters, un-
A expected refining outages
have soared in recent years,
surpassing 2,000 incidents
in 2019, quadruple 2015 levels, according
to Industrial Info Resources, a provider
of industrial process and energy market
intelligence. Insurance rates for property
damage and business interruption have
increased as much as 100% for some
refiners, resulting in energy companies
purchasing less coverage than in the past.
Although safety has always been the top
priority, refineries and chemical plants are
looking at additional automation invest-
ments to further ensure process and per-
sonnel safety to mitigate incidents, as the
cost of incidents is on the rise. Upgrading
legacy safety instrumented systems (SIS)
is often a starting place for improving
safety and adapting new digital practices
and technologies to increase safety cover-
age and mitigate risk in the field.
Improving safety with new
technologies and digital
practices makes sense
According to Offshore Reliability Da-
tabase, 42% of SIS dangerous failure
modes come from sensors. Similar
20 P.I. PROCESS INSTRUMENTATION | JULY/AUGUST 2021
sources of failures are often also seen in
chemical plants and refineries. Most of
the sensors used in SIS are traditional
instruments installed decades ago in
North America and Europe. The tradi-
tional design, installation or mainte-
nance practices for these instruments
have many challenges that contribute
to sensor failures or elevated safety
risks compared to newer technologies.
More modern technologies have made
advancements to eliminate many of
these traditional challenges by improv-
ing the robustness and smartness of
these devices. As refineries and chemi-
cal plants implement SIS upgrade proj-
ects or build new plants, applying these
new best practices and technology se-
lection improves process safety while
also improving personnel safety by
keeping personnel out of the field.
Improving measurement
sensor reliability
One of the challenges with SIS mea-
surements comes from traditional
 Figure 1: Sensors cause a significant portion of
SIS failures. All images courtesy of Emerson
flow measurement technologies like
differential pressure (DP) orifice flow-
meters. First, significant maintenance
is required to maintain traditional flow
measurement technologies like DP
orifice flowmeters due to many leak
points or freezing/plugging of impulse
lines that would result in false readings
or trips. Advancements that have been
made focus on improving the robustness
of these sensors. One of the advance-
ments includes the use of more inte-
grated DP orifice flowmeters. Traditional
orifice meters involve multiple connec-
tion hardware, pipe penetrations and
impulse lines. Figure 2 shows the num-
ber of leak points and separate com-
ponents involved to make a traditional
differential pressure flow measurement.
Integrated flowmeters are more robust
and have multivariable transmitters that
reduce the number of leak points, welds
and components compared to traditional
installations by 80%. These meters pro-
vide more reliable measurements while
reducing complexity and maintenance.
Another advancement, compact
conditioned orifice plates in integral
meters, can easily retrofit into existing
piping and replace traditional instal-
lations, as upstream and downstream
straight run piping requirements can be
reduced by 90%.
Alternatively, vortex f lowmeters
have become an increasingly popu-
lar technology displacing traditional
DP technologies for general process
and utility flow measurements. These
newly designed vortex flowmeters
JULY/AUGUST 2021 | piprocessinstrumentation.com 21

 Figure 2: Advancements in DP orifice flowmeter technologies include more integrated, compact
assemblies, reducing leak points by up to 80% compared to traditional DP orifice flowmeter installations.
provide high reliability with an inte-
gral design, resulting in no leak points,
ports, gaskets or impulse lines. Some
vortex flowmeters also have sensors
that can be removed online with-
out having to shut down the process
in the uncommon event of a sensor
failure. Vortex flowmeters are often
used in safety applications and steam
applications due to few leak points.
They also require reduced mainte-
nance in applications where impulse
line plugging or maintain heat tracing
is needed due to climate conditions or
process fluid properties. Furthermore,
newer designed vortex meters no lon-
ger require flow computers for steam
compensation calculations, making
installation simpler.
Improving measurement
sensor redundancy
Another area of improvement for SIS is
implementing measurement redundan-
cy. Lack of redundancy is common due
to the investment cost of having mul-
tiple instruments or limited installation
space. As a result, these systems often
had a common source of failure. For ex-
ample, one primary element or orifice
plate would be linked to multiple trans-
mitters. Though the electronics have
22 P.I. PROCESS INSTRUMENTATION | JULY/AUGUST 2021
redundancy, an issue with the primary
element would not be detected since
there is no redundancy for the sensor.
Newly designed technologies have ac-
counted for implementing multiple
sensors and electronics in a more cost-
effective, single device configuration, re-
ducing installation and capital costs for
a variety of measurements such as level
and flow.
For example, in tank gauging appli-
cations, level measurements are im-
portant not only for custody transfer
and inventory measurement but also
tank overfill protection. Multiple ra-
dar gauges are often needed to obtain
level measurements for the basic pro-
cess control for automatic tank gaug-
ing and for the SIS automatic overfill
prevention system (AOPS). One recent
advancement provides a unique 2-in-1
radar level solution for safety upgrades
of existing tanks with minimum modi-
fication. The innovative 2-in-1 feature
includes two radar level gauges in one
housing for independent level and over-
fill measurement compliant to API 2350
and IEC 61511 compliant solutions for
automatic and manual overfill preven-
tion systems.
Another example is for flow measure-
ment; multiple vortex meters can be
engineered in a single device configura-
tion. Adding to the benefits already men-
tioned about the robustness of vortex
meters, these dual and quad vortex flow-
meters enhance voting capabilities and
implement redundancy in a compact,
simplified manner. Dual vortex flowme-
ters protect against spurious trips using
1 out of 2 or 2 out of 2 voting. Quad vortex
 Figure 3: A unique
advancement in automatic
tank gauging systems
includes radar level gauge
with IEC 61508 SIL 3
certification for a single
device (non-redundant)
configuration that serves
as an automatic tank
gauge (ATG) and an
independent overfill
prevention sensor
simultaneously.
 Early diagnosing of sensor
or process issues
SIS failures and trips can occur because
of false readings, transmitter failures
and sensor failures as these legacy
technologies do not have diagnostic
capabilities and software solutions that
allow early detection with the sensor
integrity or even in the process pre-fail-
ure. Leveraging advanced diagnostics in
pressure, flow, temperature or level de-
vices provides early detection and quick
identification of process or device is-
sues that result in equipment failures or
inaccurate readings. These diagnostics
can reduce planned maintenance and

Automated Ball Valves

by Inline Industries
 Figure 4: Quadruple vortex flowmeters, such as
the Rosemount 8800 Series Quad Vortex Flow Meters, Inline stocks a large inventory of ball valves for isolation,
provide four independent flow measurements in a
single meter body for SIS applications. diversion and modulation applications. Whether the
valve has ISO-5211 mount pads or uses bracket
mounting, Inline’s automation facility can quickly build
flowmeters enable the highest level of
fully automated assemblies complete with actuators
safety up to SIL 3 for 2oo3 voting sys-
tems. The Quad Vortex flowmeter allows and control accessories. Electric and pneumatic
for a compact installation of flowmeters packages are available. All are factory tested.
in a single meter body. Common instal-
lations for these flowmeters in refiner-
ies and chemical plants include SIS for
steam systems, heater decoking steam
lines and multi-pass fired heater feed
flow measurements.
A recent success story involved us-
ing these meters at a Chinese petro-
chemical facility where process trips
were reduced by implementing Dual
Vortex flowmeters. The plant was us-
ing a DP flowmeter to measure steam
and feedstock to the cracker. Coke The next time you’re in the market for automated
fines would plug the impulse lines
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and resulted in unreliable measure-
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The facility replaced 52 traditional
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R

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2108PI_InlineIndustries 1
JULY/AUGUST 2021 | piprocessinstrumentation.com 23
7/14/21 3:43 PM
improve personnel safety by decreasing
unplanned failures and shutdowns.
Advanced pressure
transmitter diagnostics
Some pressure transmitters have compre-
hensive diagnostics that go beyond the
transmitter to cover both the process and
electrical loop, enabling early detection
of issues. Loop integrity diagnostics can
detect issues such as water in the termi-
nal compartment, wiring and grounding
issues, corroded terminals and unstable
power supply. Safety certified diagnostics
for the pressure transmitter can be used to
detect internal transmitter failures as well
as previously undetectable process and
electrical loop failures, reducing the safety
instrumented function probability of fail-
ure on demand. Process connections such
as plugged impulse lines, which is a com-
mon source of failure and maintenance,
can be detected early through diagnostics
as well. Beyond ensuring sensor and elec-
tronics reliability, diagnostics can also be
used to ensure process safety. The process
intelligence diagnostics of the transmit-
ter can track process standard deviation,
mean and coefficient of variation to detect
changes in process noise early by sampling
at 22 times per second. The process intel-
ligence diagnostics have been used to de-
tect abnormal process conditions such as
column flooding, cavitation, burner flame
instability, agitation loss, entrained air and
process leak detection.
A North American refinery used these
process intelligence diagnostics in the
pressure transmitter to reduce shutdown
risk. For the ultra-low NOx emission de-
sign required by regulations, the burn-
ers run very lean and are on the verge
of flame-out, making an early flame-out
detection system a requirement to pre-
vent a unit shutdown. Two solutions
were tried that did not work. The refinery
then decided to implement the pressure
transmitter advance diagnostics to mea-
sure the amplitude of the process noise
by sampling at 22 times per second and
to measure a secondary variable, stan-
dard deviation, for early detection of
flame instability. The advanced diagnostics
24 P.I. PROCESS INSTRUMENTATION | JULY/AUGUST 2021
provided a viable means of reducing the
risk of low NOx burner flame-out and
preventing heater shutdowns.
Advanced temperature
transmitter diagnostics
Unexpected failure of temperature mea-
surement can cause safety concerns or
process shutdowns. Advanced diagnos-
tics can be used to monitor processes to
identify sensor failures and intermittent or
abnormal sensor conditions to proactively
protect assets. In particular, a hot backup
capability prevents loss of measurement
signal when the primary sensor does fail by
automatically switching to the backup sec-
ondary sensor and sends an alert notifica-
tion that the primary has failed. Advanced
diagnostics include configurable process
alerts — a feature that allows alarm level
customization based on application re-
quirements. The measurement validation
diagnostic enables distinguishing valid
measurement data from false readings,
preventing erroneous readings from caus-
ing unnecessary downtime. Other diag-
nostic capabilities include thermocouple
degradation, open/short sensor diagnostic,
sensor drift alert and diagnostics related to
voltages. These advanced transmitters are
often used in critical safety loops, such as
controlling reactor temperatures to pre-
vent temperature excursions.
Advanced flowmeter diagnostics
Smart Meter Verification is an advanced
online diagnostic tool for Coriolis and
magnetic meters. Traditionally, to ver-
ify meter health, detect problems and
performance, meters would have to be
pulled offline to inspect and send for
calibration at regular intervals or prob-
lems were only detected when an inci-
dent occurred. Smart Meter Verification
is an on-demand tool that automatically
verifies meter performance without hav-
ing to pull meters offline. For example,
Smart Meter Verification of Coriolis
meters detects problems like corrosion,
erosion, two-phase flow and abnormal
flow ranges earlier to mitigate meter
damage or measurement accuracy. The
Smart Meter Verification diagnostic
can extend full proof-test intervals by
providing 91% coverage of undetected
dangerous failures in-situ. A large global
chemical manufacturer captured these
benefits by leveraging Smart Meter Veri-
fication for Coriolis meters to improve
safety by eliminating human factors and
loss of SIS measurement function during
proof-testing. Traditionally, proof-testing
would involve taking the meter out of
service and bringing it to a calibration
facility; now inline verification of meter
accuracy can be done in-situ, improving
both process and personnel safety.
Advanced diagnostics and software
level solutions for proof-testing
Regular proof-testing is an essential re-
quirement for SIS in liquid level mea-
surement applications, as it ensures
that they are operating to the necessary
safety integrity level (SIL). Traditionally,
proof-testing has been performed with
multiple technicians in the field and one
in the control room, verifying the safety
system reaction. This requires a consid-
erable amount of time and effort, can
pose safety risks to workers who need
to climb tanks to perform the test, could
take the process offline for an extended
period, and can be prone to errors.
However, the technological advances
of the latest generation of level mea-
surement technologies are now en-
abling proof-testing to be performed
remotely and without interrupting the
process, making the procedure much
quicker, safer and more efficient.
For the latest vibrating fork level detec-
tors, remote partial proof-testing is per-
formed by issuing a HART command from
the control room. Upon receiving the com-
mand, the device enters test mode, cycling
the output through wet, dry and fault states,
then returning to normal operation. Since
the test can be performed in-process, it can
take less than one minute to complete.
With advanced guided wave radar
transmitters, an adjustable verifica-
tion reflector fitted to the probe is used
to simulate a high level in a tank. This
avoids the need to fill the tank just to
test the instrument and eliminates the
 risk of a spill if a device fails to activate
during testing. To remotely proof-test
the latest non-contacting radar level
transmitters and gauges, a high-level
alarm can be verified using a simulated
reference reflector. The proof-testing
procedure is simplified through the
use of dedicated software, which leads
the operator through the various pro-
cedures step-by-step and only requires
them to input a straightforward se-
quence of settings and commands.
All of these newer methods save time
and money while providing an easier and
safer, more digital way for proof-testing
with minimal process interruptions, elim-
inating the need to climb tanks, and ex-
tending time between proof-test intervals.
Advancing and digitalizing
safety makes sense
Historically, safety has always been a
strong investment focus for refineries
2101PI_SpitzerBoyes 1
and chemical plants but will continue
to be an ongoing focus area as the insur-
ance coverage costs rise and insurance
coverage decreases. With newer and
more comprehensive ways to mitigate
safety risks, refineries and chemical
plants should reevaluate their approach
to safety. With newer, more robust and
smarter measurement technologies
now embedded with advanced diagnos-
tics and digital work practices focused
on ensuring measurement reliability for
both the sensor and electronics, it makes
sense to implement a more holistic ap-
proach to protecting and covering the
safety of personnel and assets.
References
1. https://www.reuters.com/article/
us-usa-refineries-insurance/u-s-
refiners-chemical-makers-pare-
insurance-coverage-as-accidents-
boost-costs-idUSKBN1ZT0FB.
Check Valves
...to other fluids.
• Customizable
• Up to 260°F
• Material options
Neoperl, Inc. | Waterbury, CT
info@neoperl.com | www.neoperl.com
12/15/20 2:39 PM
2105PI_Neoperl.indd 1
Meha Jha is a refining indus-
try marketing manager for
Emerson. Since joining Em-
erson, she was selected for
Emerson’s Engineers in Leadership Program,
where she broadened her refining expertise
by working on projects related to mass bal-
ance and utilizing measurement solutions to
improve energy efficiency and safety. She
earned a Bachelor of Science in chemical en-
gineering from Auburn University.
Julie Valentine is the director
of global refining for Emerson’s
Automations Solutions busi-
ness. She first joined Emerson
in 1993. Valentine has authored numerous
technical papers on various applications of
flow technology in the refining industry and is
a co-inventor on two U.S. patents. She holds
a Bachelor of Science in chemical and petro-
leum refining engineering from the Colorado
School of Mines.
From drinking water…
• Sizes 1/4” to 2”
• Up to 200°F
• Global approvals
JULY/AUGUST 2021 | piprocessinstrumentation.com 25
3/31/21 1:03 PM
 CORIOLIS FLOWMETERS
CASE STUDY:
Gore Nitrogen finds cost-effective
flow measurement solution
Coriolis flowmeter provides accurate readings for non-Newtonian fluids.
By Endress+Hauser
erving the midcontinental
S region of the United States,
Gore Nitrogen specializes in
hydraulic fracturing, acidiz-
ing and nitrogen services. The com-
pany takes pride in providing oil and
gas customers with high-quality and
cost-effective solutions, along with a
high level of transparency. Gore Nitrogen
provides repeatable and accurate viscos-
ity measurements when creating frac
fluids. But this is a challenge because
the company handles non-Newtonian
fluids with viscosities that fluctuate with
changing pressure and temperature.
This makes Gore Nitrogen’s readings
and instrumentation incredibly impor-
tant to maintain optimal safety and
quality. If the company does not adjust
to the current viscosity before pumping
26 P.I. PROCESS INSTRUMENTATION | JULY/AUGUST 2021
fluid and frac gel down the wellbore, it
could cause product damage.
To compensate for viscosity fluc-
tuations and to maintain high-quality
products, Gore Nitrogen used a man-
ual measuring process. Although this
worked, it did require constant atten-
tion from personnel — which was both
costly and timely. So, Brandon Bensch,
Gore Nitrogen’s IT director, reached out
to Endress+Hauser for a different solu-
tion. Endress+Hauser recommended
the Promass I 300 Coriolis flowmeter
and worked with the Gore Nitrogen
team to get the new technology imple-
mented and running smoothly.
Challenge
Before Bensch made the switch to the
Promass I, Gore Nitrogen operators
 Gore Nitrogen headquarters
in Seiling, Oklahoma
All images courtesy of
Endress+Hauser
were taking manual samples every 10
minutes and running multiple tests to
gauge the viscosity measurement. This
required constant use of manpower, but
the tests were necessary to maintain ex-
act product quality for customers. Since
the products were non-Newtonian flu-
ids with fluctuating viscosities, opera-
tors could not just set the levels. They
instead had to make timely corrections
to adjust for variations, otherwise qual-
ity and safety issues could occur.
Solution
Gore Nitrogen ran gel trial tests to de-
termine a proper correction for the
fluctuating viscosity and reached out
to Endress+Hauser for assistance.
Endress+Hauser’s flow product busi-
ness manager, Mason Flannery, analyzed
the results and recommended the Pro-
line Promass I 300 Coriolis flowmeter in
conjunction with the RIA46 field indica-
tor. Non-Newtonian fluids often present
a challenge for accurate measurement
and repeatability due to changing pro-
cess conditions. However, the Coriolis
measuring principle operates indepen-
dently of physical fluid properties such
as viscosity or density.
Using the gel trial tests with the Pro-
mass I, Gore Nitrogen was able to get
a repeatable measurement. The Pro-
mass I also made it possible to display
the measured value in units and scales
familiar to the company’s operators.
These and other features reduced any
potential challenges that could occur
when adopting a new technology.
“The Promass I 300 has been an extreme
blessing and benefit for us,” said Bensch.
“Our customers love seeing the real-time
data of the gel measurements and appre-
ciate that next level of transparency,”
Results
The Gore Nitrogen team has seen great
results from the Promass I 300 Coriolis
flowmeter. The new setup eliminates
the need for manual testing and frees
up resources, saving both manpower
and time. Since the Promass I is built
to withstand fluctuating conditions,
operators no longer need to manually
pull samples every 10 minutes or run
constant tests for measurement read-
ings. Instead, they make the corrections
automatically via the control system,
 A Promass I
300 flow valve
installation in a Gore
Nitrogen quality
control unit.
 The Proline Promass I 300
Coriolis flowmeter combines
inline viscosity and flow
measurement with a compact,
easily accessible transmitter.
providing improved control, accuracy
and overall quality for each job.
Since the Promass I 300 provides
multivariable measurements including
flow, density, temperature and viscos-
ity, Bensch was pleased to be able to
gather all the data from a single device.
This eliminated the need for multiple
transmitters and enhanced the overall
usefulness of each measurement. Finally,
one of the benefits Bensch and the Gore
Nitrogen team appreciated the most was
the ability to provide customers with
greater value. Gore Nitrogen was able to
reduce the overall manpower for each
job, free up the technicians so they could
focus on other improvements, pull live
readings and real-time data from the dig-
ital technology, and reduce overall costs.
Bensch was excited to share how these
improvements provided a greater level of
 An RIA46 Field meter
with control unit
transparency and cost savings for Gore
Nitrogen’s customers.
“The more automatic the process is,
the better,” Bensch said. “With the web
server built in, we can now see every-
thing remotely. At any given time, we
can log in and check settings and see
how the system is reading. That provides
big savings on technicians in the field,
greater transparency for the customer
and allows for additional observations
to prevent issues like leaks and spills.”
Components:
• Promass I 300 Coriolis flowmeter
• RIA46 field indicator
Benefits at a glance:
• Saves time and overall cost
• Reduces batch time
• Eliminates need to pull physical
and manual samples
• Gathers data and measurements
in real time
• Reduces human error through
process automation
• Multivariable flowmeter provides
multiple measurements out of a
single device
• Environmentally conscious by
reducing risk of spills or leakage
• Utilizes the RIA46 to indicate
readings in a familiar format
JULY/AUGUST 2021 | piprocessinstrumentation.com 27
 VIBRATION ANALYSIS & PREVENTION
Prevent asset failures using
clues from vibration data
By collecting vibration data over time,
maintenance teams gain the ability to compare
measurements and failure mode patterns.
By John Bernet, Fluke
an you hear that? That’s the
C
sound of your machine failing.
It is not a question of if a
machine will fail, but when.
And, by the time you hear excessive or
abnormal vibration, it is likely that dam-
age has already been done. Vibration data
can indicate conditional change. Col-
lecting and trending that data enables
28 P.I. PROCESS INSTRUMENTATION | JULY/AUGUST 2021
maintenance professionals to identify
potential failures and to prevent them
before downtime or damage occurs.
Monitoring assets to identify when
vibration patterns change — and how
much they change — can tell mainte-
nance teams a lot about the health of
a machine. The goal of vibration moni-
toring and analysis is not to eliminate
vibration completely, because all rotat-
ing parts vibrate. Instead, the goal is
to identify changes in that vibration.
Excessive vibration can indicate prob-
lems and lead to premature wear of
components. Once identified, changes
in vibration patterns can be interpreted,
and the fault behind the changes can
be determined.
Route-based maintenance is time-
consuming, and regularly visiting assets
in hard-to-reach or dangerous areas
adds risk. Vibration sensors can screen
assets so maintenance teams can moni-
tor them remotely, accessing vibration
data from the sensors using a smart-
phone or desktop computer. By reduc-
ing their trips to assets in hard-to-reach
or dangerous areas, teams stay safer
and have more time to devote to the
most important things.
There are sensors suitable for any as-
set type or budget. Some take detailed
readings frequently and convey a great
  Figure 1: Vibration sensors placed on machinery
can detect vibration abnormalities.
All images courtesy of Fluke Corporation
deal of data. Battery-less sensors, which
are smaller and use less energy, take
quick snapshots of asset data.
Sensors placed on machinery’s bear-
ings can measure the vibration frequen-
cies that are transmitted from the ro-
tating shaft through the bearings to the
surface of the machine. This data can
then be transmitted from the sensor it-
self to software that will trend the data
and allow users to analyze it. Alarms
can be sent to alert maintenance teams
when a machine’s condition changes.
And when analysis of the data indicates
a fault, maintenance teams can choose
to perform further testing, gather further
data or schedule a repair. This decision
should consider the history of the asset,
its criticality and the severity of the fault.
Vibration analysis is a key piece of a con-
dition-based maintenance strategy.
Vibration analysis as part of a
condition-based maintenance
(CBM) strategy
Condition-based maintenance does not
wait for things to break down or determine
“Condition-based maintenance involves using techniques such as
vibration monitoring and analysis to hear the clues that machines
are giving about their own health and performance.”
when to perform maintenance actions
based on calendar dates. Instead, condi-
tion-based maintenance involves using
techniques such as vibration monitoring
and analysis to hear the clues that ma-
chines are giving about their own health
and performance. When machine condi-
tion changes, detecting those changes and
determining their cause determines how
maintenance teams should respond —
and when.
Vibration analysis has been an estab-
lished practice for decades. As a result
of this, there are robust algorithms and
rules that exist to identify and diagnose
machine faults. There are characteristic
patterns in vibration signals. Reading
and recognizing those patterns takes ex-
tensive training and experience, but 90%
of machine faults fall into four common
categories: misalignment, imbalance,
looseness and bearing wear. Instead of
trying to learn to identify every possible
fault, focus on the four most common.
Misalignment
When machine shafts are out of line,
damaging forces will cause increased
mechanical loads, energy waste and ad-
vanced wear on components. Worst-case
scenarios can include cracked or broken
shafts — not only a problem for the asset
but also a potential safety hazard that
puts maintenance personnel at risk.
Imbalance
A heavy spot on a shaft causes abnormal
vibration when the unbalanced weight
rotates around the machine’s axis, lead-
ing to increased bearing and seal wear,
energy waste and poor production.
Looseness
A shaft, foundation or component can be-
come loose, causing potentially destructive
vibration and increasing the wear of bear-
ings and seals. Looseness can also result in
 Figure 2: Because vibration analysis has been
an established practice for decades, there are
robust algorithms and rules that can be used to
identify and diagnose machine faults.
JULY/AUGUST 2021 | piprocessinstrumentation.com 29
  Figure 3: 90% of machine faults fall into four
common categories: misalignment, imbalance,
looseness and bearing wear. Rare machine faults
do happen, but they are just that: rare. Instead
of learning about every fault, learn to identify the
most common types.

improper fit between components, loose
bolts or baseplate problems.
Bearing wear
Excessive loads, poor lubrication or in-
stallation, or other machine faults will
cause bearing wear, eventually leading
to failure. Bearing rollers traveling over
a worn or damaged area can cause
vibration, as can a drive belt that is
breaking down.
Preventing failures and unplanned
downtime with vibration analysis
Screening assets to detect vibration
abnormalities prevents unplanned
downtime and reduces the time that
teams spend on calendar-based main-
tenance activities that assets do not
yet need. By collecting vibration data
over time, maintenance teams gain
the ability to compare measurements
and failure mode patterns. Identifying
abnormalities and diagnosing faults in
advance means they can be planned
for — reducing uncertainty, downtime
and maintenance spending. And be-
cause planned maintenance activities
carry less risk than urgent, reactive re-
pairs, reducing unplanned downtime
improves worker safety.
Vibration changes can signal when
machines are not operating in peak
condition and, instead, are in need
of intervention or repair. Underlying
causes of vibration can shorten the life
of equipment and components. Finding
and fixing impending faults before they
cause damage or downtime means as-
sets can be kept up and running — in
peak condition — longer. This directly
benefits the bottom line.
Early warnings give teams the op-
portunity to focus on the machines that
need attention and to plan on the best
time to fix failures. Moving away from
a reactive maintenance strategy helps
teams optimize their time and energy
and increase the availability and reli-
ability of their assets.
As a mechanical application
and product specialist with
Fluke Reliability, John Bernet
works with customers from
all industries to successfully implement their
reliability programs. He has more than 30
years of experience in the maintenance and
operation of commercial machinery and as
a nuclear power plant electrician in the U.S.
Navy. He holds a Category II Vibration Analyst
certification and is a Certified Maintenance
Reliability Professional (CMRP).

BREAKTHROUGH
2021

PRODUCTS AWARDS

SUBMIT YOUR PRODUCT TODAY!

Processing’s annual Breakthrough Products Awards honor
innovative technology solutions that made significant contributions
to improvements in the process industries within the past year.

Nominations are now open.

Visit www.processingmagazine.com/breakthrough-products
to submit your entry by September 30.

30 P.I. PROCESS INSTRUMENTATION | JULY/AUGUST 2021

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