Process Plant and Equipment UP-

TIME
f o r P l a n t O p e r a t o r s
From www.feedforward.com.au – Process plant and equipment engineering education for operators and maintainers.
Volume 3 Edition 5 topics
Key topics for the month
• Is your wet scrubbing tower working?
• Metering & dosing pump operation.
Special features
• Process Control Talk
Flow meters – don’t believe what they tell you.
• From the Mechanical Workshop
Plant compressed air waste reduction.
• Asset Management
Work Within The Design Limits
Process Control Talk
Flow meters – don’t believe what they tell you.
Abstract
Flow meters – don’t believe what they tell you. A flow
meter is an instrument that measures the amount of fluid
(liquid or gas) that passes through it. The meter in the pipe To prove a flow meter is accurate it is necessary to measure
is the detecting device and increases the count when a
specific quantity of fluid passes by. There are several types For liquid this requires the use of either accurate scales to
of flow meters in common use. They include magnetic flow
meters, vortex flow meters, mass flow meters, turbine flow
meters, rotor blade meters, paddle flow meters, and
ultrasonic flow meters. Usual the quoted accuracy on the
flow meter specification sheet is for water at 20oC. However
when the meter is installed in a process application it is
unlikely that the meter will meet the quoted accuracy
without site-specific calibration. Keywords: calibration,
certified test equipment, flow meter accuracy.
The manufacturer performs laboratory trials of its equipment
to insure the flow meter meets their claims for accuracy.
Since the manufacturer does not know where their meter will
be used they standardise the tests by using water at known
conditions. Unless the meter is used in a situation identical by appropriate methods and the error on the measured
to the laboratory conditions the given accuracy is unlikely to calibration is within the tolerance of the meter. Beware that
be achieved.
PROBLEMS THAT PRODUCE FALSE READINGS
Below are listed problems that have occurred with flow
meter installations that produced false results.
• PLC scan rate is less than meter pulse rate and meter pulses
are not counted.
• Sediment wears away the meter’s internal clearances on
the impeller, rotors or paddles and the fluid slips past.
• Solid items, like bits of plastic bag, gloves, rags, parts from
other equipment in the process and polystyrene coffee
cups, get jammed in the meter. Always install a strainer
up-stream of meters with mechanical parts or protrusions
into the flow, such as vortex flow meters.
a n d M a i n t a i n e r s
• Product density is substantially different to water.
Examples are 50% sodium hydroxide (s.g. 1.5), 98%
sulphuric acid (s.g. 1.8).
• Software adjustment factors added in to make the meter
produce the required results are lost or changed.
• Product temperature varies and alters the product density.
In this case it is necessary to factor in temperature effects
on the density.
• Temperature changes in the meter electronics or associated
electronic equipment in the control loop caused by the
process fluid or local environment conditions. Electronic
items change behaviour with temperature changes.
• Broken turbine wheel, rotor blades or paddles.
• Leaks under magnetic flow meter linings at liner joints
destroy internal circuitry
• The meter accuracy varies as the flow rate varies.
• Meter position or orientation allows bubble inclusion in the
liquid (two-phase flow). When measuring liquid the meter
must only see liquid and absolutely no gas. Good practice
is to place the meter 10 pipe diameters downstream and 5
pipe diameters upstream of turbulence creators. E.g.
valves and elbows.
CALIBRATE TO PROVE ACCURACY
that what is counted through it has actually come out of it.
measure the weight of the volume put through the meter, or
an accurate volume to prove that a given amount has actually
passed through the meter.
The calibration will need to be done at several different flow
rates across the range of flows experienced in the process.
This is necessary to confirm the extent of the error at low
process flows through to high process flows.
To insure accurate in-field calibration it is necessary that the
calibrating equipment is of even higher accuracy. If using a
scale to measure weight insure the scale has been calibrated
accurately and the scale’s divisions will give you the
resolution you require. If measuring into a known volume,
such as a tank, insure the tank has been accurately calibrated
dipping a tank to measure its level has a plus or minus 1-mm
error even for highly experienced persons.
When it is absolutely critical to have certainty in a flow
meter’s reading it is necessary to instigate regular checks of
the meter using recognised industry standards and practices.
Typically they include the following:
• Use of governing body registered procedures.
• Use of an independent, qualified and certified third party to
conduct the tests.
• Tested and certified highly accurate test equipment, test
meters and gauges.
• Certified, experienced, competent testing personnel.
If you are paying to receive product from others through
their flow meter it is advisable that you get quarterly

FEED FORWARD PUBLICATIONS, PO Box 578, BENTLEY, West Australia, 6102 Web: www.feedforward.com.au E-mail: info@feedforward.com.au
Because the authors, publisher and resellers do not know the context in which the information presented in the flyer is to be
used they accept no responsibility for the consequences of using the information contained or implied in any articles.
calibration checks done on it. Install your own flow meter to
confirm their results and to insure they maintain its accuracy.
Keep copies of flow meter calibration records from
commissioning and all subsequent tests and trend them on a
graph to observe if the meter remains accurate throughout its
operating life.
Mike Sondalini – Equipment Longevity Engineer
Is your wet scrubbing tower working?
ABSTRACT
Is your scrubbing tower working? A wet scrubbing tower is
used to clean odors, particles, mists and vapours from a gas
stream. The gas is forced through the tower. As it moves
from inlet to outlet it is washed and cleaned. The washing is
done with suitable chemicals that remove the active
components in the gas flow. The gas is cleaned to
environmentally acceptable levels and discharged to
atmosphere. Keywords: packed tower, packing, fill, mist
eliminator.
OPERATION OF A WET SCRUBBING TOWER
Figure No. 1 shows a simplified drawing of a packed
scrubbing tower. The dirty gas comes in the bottom of the
tower. Sprays within the tower wet the internals of the
tower. The gas is forced through a bed of packing ‘fill’ that
breaks the gas flow into many small flow streams. The
numerous gas streams pass around the wet fill and make
contact with the scrubbing solution. The packing is usually a
small twisted, convoluted plastic or metal wire shape.
During the contact active components in the gas are removed
either by chemical reaction or, in the case of particles, by the
drenching they receive from the sprayed liquid.
Figure No. 1 A Wet Scrubbing Tower.
When the gas leaves the scrubbing bed it is wet. Liquid
droplets and mist carried with the gas are then forced
through another bed of packing, or mist elimination pads, to
remove most of the moisture. As with the scrubbing bed, the
elimination bed forces the wet gas to break-up into numerous
small streams. The impact on the elimination bed material
knocks the mist out of the gas stream. The dampness gathers
on the bed material to form droplets that fall back into the
tower.
The liquid sprayed into the tower must neutralise the
components in the gas stream that are to be removed. For
example if the gas stream contained acid mist, the scrubbing
FEED FORWARD PUBLICATIONS, PO Box 578, BENTLEY, West Australia, 6102 Web: www.feedforward.com.au E-mail: info@feedforward.com.au
Because the authors, publisher and resellers do not know the context in which the information presented in the flyer is to be
used they accept no responsibility for the consequences of using the information contained or implied in any articles.
liquid would be an alkaline solution of sufficient strength to
neutralise all the acid. If there were concerns that the
alkaline solution would itself carry-over into the atmosphere,
it would be necessary to install an additional wash to clean
the alkaline mist. A second tower spraying clean water
could do this.
TESTING SCRUBBING TOWER PERFORMANCE
The quality of the cleaned discharge gas reflects the
scrubbing tower’s performance. To prove the tower is
working properly, the discharge gas stream is sampled and
tested for the amounts of the reactive components remaining
in the flow. The test results must be below the relevant
environmental guidelines.
Measuring the strength of the scrubbing solution can also be
used to monitor the tower’s performance. As the gas stream
is cleaned of the offending components the scrubbing
solution changes its chemistry. This change in chemistry can
be monitored and provides an indication of the tower’s
performance.
The variables that affect scrubbing tower performance are:
• Residence time in the tower scrubbing bed. The gas
flow needs to be sufficiently slow to provide time for
the contaminants to contact the scrubbing liquid.
• Sufficient concentration of scrubbing reagent in the liquid to
react with gas stream contaminant.
• Insufficient contact surface area because packing in the bed is
missing, uneven or was never added to the tower.
ISSUES WITH OPERATING SCRUBBING TOWERS
Listed below are a number of important issues that need to
be addressed when using packed-bed wet scrubbing towers.
• Blocked flow path forcing gas flow through only a part of
the scrubbing bed. The packed bed must be uniform across
and throughout its depth. Rat holes and blockages in the
packing will allow the gas stream to bypass the cleaning or
elimination processes.
• Blinded packing can occur if process contaminants start
clogging-up the passages between the packing elements. It
may be possible to backwash the contamination or
chemically remove it. Insure the chemicals used do not
destroy the packing.
• Blocked vent lines from process equipment to the scrubber
can occur in processes containing fine, damp particulate.
Keep the duct velocities high so the particulate cannot
easily settle out and coat the walls. Where regular
blockage occurs it is necessary to find ways to backwash or
chemically clean the duct regularly.
• The packing must be prevented from being blown out of
the bed by abnormally high gas flows. A violent rush of
gas created by the process reaction may dislodge the
packing and even carry bits of it away. Retaining screens
may be required on top of the bed. Insure the mesh size
and clearances around the screens do not allow fill to
escape past them.
• Wet discharge from the tower will settle back onto
neighbouring equipment in the plant and hasten corrosion.
• Scrubbing liquid flows unevenly through the packed bed.
The spray shape is critical to full and proper wetting of the
packing in the bed. The spray cone needs to be a complete
sheet of liquid impacting the inside wall of the tower just
above the top of the scrubbing bed.
• A flooded scrubber drowns the scrubbing bed. Drainage
from the tower back to the storage tank must be sufficient
to always stay below the inlet nozzle to the tower. If the
 liquid level in the sump rises above the inlet nozzle it will
flood back into the process.
• The materials used to make the tower and scrubbing circuit
must be chemically and physically compatible with all the
chemicals and conditions that will occur. Beware if the
process temperature can get hot enough to melt plastic
packing. If this occurs the melted plastic drops to the
bottom of the bed and blocks it. The loss of packing and
the blockage by the plastic stop the gas flow from being
properly cleaned.
• Size the delivery ducting to the tower and the extraction
fan to maintain mists and particles in suspension. Slope all
ducting with sufficient fall to be self-draining and self-
cleaning in the appropriate directions.
• Where possible it is better not to use a fan but instead
totally seal the delivery ducting and use the natural
pressures generated in the process to force the gas stream
through the tower. This ‘natural pressure’ approach saves
on equipment and maintenance and minimises the gas
discharge to the least amount necessary.
Mike Sondalini – Equipment Longevity Engineer
Metering & Dosing Pump Operation
ABSTRACT
Metering and dosing pump operation. Any positive
displacement pump can be used as a metering or dosing
pump. The purpose of these pumps is to inject a known
volume of liquid into a process stream. The primary
requirement is that over a given period of time the pump
consistently delivers the same amount of liquid. Keyword:
gear pump, piston pump, helical rotor pump, diaphragm
pump, peristaltic (hose) pump, additive, dosing rate.
TYPES OF METERING AND DOSING PUMPS
Positive displacement pumps used for dosing duties include
diaphragm pumps, peristaltic (hose) pumps, helical rotor
pumps, gear pumps and piston pumps. Piston pumps are the
type commonly known as metering or dosing pumps. The
degree of accuracy in the delivered quantity is low with
diaphragm pumps, better with hose pumps, good with rotor
pumps, excellent with gear pumps and the best with piston
pumps. The cost of each pump type rises in the same order.
Pumps from the lower order of the list suffer from back
pressure efficiency losses. When they work against a high
pressure some of the liquid in the pump does not actually get
ejected from the pump. The higher the pressure the less
liquid is ejected. This is exactly the opposite of what is
required from a metering pump. But for low pressure, low
accuracy applications they are cost effective.
Helical rotor and gear pumps perform well when dosing is
required over longer periods of time. The most accurate
metering pumps are the piston pumps. Small chambers in
the pump are squeezed empty by a solid piston moved
mechanical or hydraulically. The stroke length and/or the
stroke frequency are adjustable.
Accurate dosing leads to less waste of expensive additives
and translates to lower costs as only the exact amount is
used.
DOSING SYSTEM DESIGN AND INSTALLATION
The components of a dosing system are the supply tank, the
dosing pump, pressure relief device, the flow control
FEED FORWARD PUBLICATIONS, PO Box 578, BENTLEY, West Australia, 6102 Web: www.feedforward.com.au E-mail: info@feedforward.com.au
Because the authors, publisher and resellers do not know the context in which the information presented in the flyer is to be
used they accept no responsibility for the consequences of using the information contained or implied in any articles.
equipment and the injector. Figure No. 1 shows a drawing
of a simple dosing system.
Measuring the quantity to be dosed can be done by putting
the required amount into a calibrated buffer tank and
pumping it dry or by installing a level detector in the supply
tank and controlling the pump’s stop/start automatically.
Using a flow meter to measure the pump discharge is usually
too inaccurate for the small flows and quantities involved.
The surging flow from pump-action pumps makes accurate
flow measurement impractical.
It is necessary to include a means to adjust the flow rate from
the pump. This can either be built into the flow control
system or it is a function offered with the pump. Motor
frequency controllers and regulating valves with a by-pass
back to the tank are common flow adjustment methods.
If surge flows from the pump cause problems a pulsation
dampener can be installed in the discharge line. This is a
small pressure vessel with a pressurised space inside. As a
surge arrives the pressurised space compresses and absorbs
the impulse into the dampener. The pressured void applies a
constant pressure on the liquid and the discharge from the
dampener is constant and steady.
Figure No. 1 Dosing Pump System Requirements
When installing the dosing pump provide room for
inspection and maintenance access to the equipment. Keep
the discharge pipe length from pump to injector as short as
possible though positive displacement pumps can generate
high pressures and will force liquid a long distance. Long
discharge pipes should be one size larger diameter than the
connection to the pump outlet. Keep the suction line short
and one diameter larger than the inlet connection to reduce
the chance of pipe friction losses causing low pressures
leading to pump cavitation.
Piston pumps can produce high accelerations in the suction
line as the piston strokes and the sudden fast movement can
cause cavitation. Though positive displacement pumps will
draw liquid from a distance, it is best to maintain a
pressurised suction. Mount the pump below the lowest level
the liquid falls to in the tank and insure the suction line
slopes downward all the way to the pump.
The injection point into the process should project into the
tank or the pipe. On a large diameter pipe inject the dosed
chemical into the center of the pipe to provide the best
chance of mixing thoroughly. Injecting into the middle of
the flow is not so important on small-bore pipes because the
flow streams in the pipe are close together and tend to mix.
Be aware of the dilution effects when an additive is injected.
Effects such as increased corrosion rates, temperature rise
and vapour release from chemical reactions can occur when
the additive contacts the process liquid.
ISSUES WITH EACH TYPE OF PUMP Mike Sondalini - Equipment Longevity Engineer
Summarised below is a list of some of the issues that affect
the various types of dosing pumps. From the Mechanical Workshop
Pump Type
Diaphragm
Advantages
• Low purchase cost
Disadvantages
• Inaccurate dose rate
Plant compressed air waste control.
Pump • Easy, low cost against high pressure ABSTRACT
maintenance • Requires separate filtered,
• Good for batch dosing dry air supply
Plant compressed air waste control. Every compressed air
• Pressure relief not • Maximum discharge system will eventually develop leaks from connectors and
necessary pressure is less than air redundant pipelines. Compressed air is very expensive to
• Operates on plant supply pressure make. It is necessary to institute regular inspections for air
compressed air • Poor discharge flow
• No need for pressure control leaks and fix them immediately. Keywords: pressure loss,
relief as pump stops if • Sediment/solids jam flow energy loss, air compressor, pressure switch.
dead headed direction balls open
• Pulsing flow AIR LEAKS ARE EVERYWHERE
• External flow control Air leaks in a compressed air system can be at numerous
required
• Only course flow
locations and for numerous reasons. Below is a list of the
adjustment possible many ways and places air leaks can occur.:
• Rapid stroking causes • Threaded joints cross-threaded, with mismatched threads
directional balls to deform (e.g. BSP forced into NPT connections) loose threads,
• Moisture in air supply
jams/corrodes shuttle
unsealed threads, worn threads.
valve • Loose or mismatched flanges.
• Material to chemical • Broken push-in air fittings or damaged plastic hose ends.
compatibility is critical • Bent over ends on redundant pipes.
Peristaltic • Good for batch dosing • Pulsing flow • Plastic lines to actuators cracked when bent over to isolate
(hose) Pump • Conceptually simple • Expensive maintenance
actuated valves during maintenance.
• Rubber hose chemical
compatibility is critical • Cracked or squashed plastic pipe or metal tubes.
• Hose wears and squashes • Ultraviolet light damage to plastic pipes from sunlight.
• Sediment/solids damage • Chemical attack or corrosion.
hose internal walls • Plastic lines burnt by weld splatter.
• Pressure relief needed • Plastic lines melted on hot equipment or pipes.
• External flow control • Valve stems and valve actuator stems.
required • Connections to equipment.
• Fine flow adjustment is
• Valves that no longer seat properly.
not possible
• Valve balls can break, pit, • Valves left partly open.
split • Failed automatic drains.
Helical Rotor • Slow moving rotor • Expensive maintenance • Leaking air receiver doors and attached fittings.
Pump means little wear • Rubber stator chemical • Passing pressure relief valves.
• Accurate steady flow compatibility is critical
• Good flow adjustment • Pressure relief needed INSTIGATE REGULAR INSPECTIONS
possible • External flow control The only way to stop air leaks is to find them and fix them.
required One method is to get a spray bottle of soapy water and walk
• Rubber stators wear faster
if solids present the pipe work testing every joint and connection by spraying,
Gear Pump • Very accurate • No sediment/particulate or wiping, the soapy water onto it and looking for bubbles
consistent dosing permitted into pump forming as the air leaks out. If the leak is substantial it can
• Steady flow rate • Pressure relief needed be heard. Highly sensitive listening devices are also
• Comparatively • External flow control
inexpensive required available but these are expensive and more time consuming
• Low maintenance if • Pressure drops as bushes than the soapy water method.
chemical wear and allow gap
compatibility is between teeth to widen A full inspection of the compressed air system should be
addressed done every twelve (12) months. Operators and maintainers
Piston Pump • Most accurate dosing • Expensive to buy need to report every air leak they see and raise a work order
• Very low flow rates • Pressure relief needed
possible
to repair it.
• Purpose designed for
dosing service
INSTIGATE GOOD STANDARDS
• In-built fine, flow Using good engineering, installation and maintenance
control standards and practices can prevent a lot of air leaks.
Critical air supply systems should be fully welded.
CALIBRATION Important connections and pipes to equipment should be of
Pumping a known quantity of liquid into the process stream stainless steel tubing and ferrule cone connectors or
and measuring the time taken is how a dosing pump is pressure-on-face sealing connectors. Mixing fittings and
calibrated. A clear, graduated column of sufficient volume materials must be prevented. All connections should be in a
is installed to supply the pump. The column is filled with position that can be easily reached for inspection and repair.
liquid and the pump is started. The drop in level over a
period of time is recorded. From the time difference and the Train installers in the proper methods of sealing threads.
change in level the flow rate can be calculated. Changes to Review old engineering piping standards and update them
the flow rate are done by adjusting discharge valve positions with better practices and then reissue them to the engineers
or by changing the pumping speed/stroke. and maintenance people. Explain the changes and train
people in their use.

FEED FORWARD PUBLICATIONS, PO Box 578, BENTLEY, West Australia, 6102 Web: www.feedforward.com.au E-mail: info@feedforward.com.au
Because the authors, publisher and resellers do not know the context in which the information presented in the flyer is to be
used they accept no responsibility for the consequences of using the information contained or implied in any articles.
REDUCE THE AIR PRESSURE
In order to minimise the cost of air leaks, run the compressed
air at the lowest pressure possible. Usually the air
compressor has a pressure switch that covers a range of
pressures. With approval from Operations conduct trials to
see the effect on equipment of using a lower set pressure and
set the switch to the lowest acceptable operating pressure.
Mike Sondalini – Equipment Longevity Engineer
For example the designer assumes that bearings will be
lubricated exactly as the bearing manufacturer states they are
to be lubricated. That they will not experience forces greater
than they were designed to take. Another example is that the
designer expects wearing parts to be replaced when their
operating life has come to an end. He has to make these
assumptions to be able to build his design for a reasonable
cost using the materials available.

Asset Management A process, plant or equipment operator and maintainer has

Work Within The Design Limits the job of nurturing their plant and equipment so that it
operates within the service limits set by the designer. If the
equipment runs outside of those limits the problem must be
ABSTRACT
corrected quickly and brought back into tolerance or else it
Work within the design limits - Once equipment or a process
will fail and breakdown. When the plant stops too often the
is allowed to run outside it’s design limits it will fail quickly.
business will lose money, it will lose customers and
The only way to get long-lived, well operating plant and
eventually employees will be put out of work.
equipment is to keep its individual components working
within their service limits throughout their life. Keywords:
Mike Sondalini – Maintenance Engineer
training manual, procedures, operator manual

The best way to guarantee long equipment life and reliable

operation when in service is to run and maintain plant items
exactly as the item’s designer planned for it to be done.

An operator and maintainer’s duty is to know the design

limits of their process equipment and keep it within the
acceptable design conditions. They need to know the
engineering of their equipment so that they can operate and
maintain it in the right ways to keep it working as designed.

Find out how the designer wanted it done. Read the manuals
and understand exactly what to do and especially why it is
done that way. Make the knowledge known to everyone that
uses or maintains the equipment, make sure it becomes
standard operating practice and make sure that it is never
forgotten by anyone. This approach will give you
confidence that your plant and equipment will work properly
all its life.

If necessary rewrite the manufacturer’s manuals into step by

step procedures for operators to follow and step by step
procedures for maintainers to follow. Use pictures and
diagrams to explain what is happening in the equipment or
the process. Explain in details and train people to
understand what they must know to run the operation well
and near to perfection.

Equipment, machinery and processes used in industrial

plants and facilities are built to known, well-understood
engineering principles. The process and equipment designer
uses them to create equipment, machinery and processes.
The designer expects that the operators and maintainers
responsible to run the plant, processes and equipment
operate and maintain them so that they perform exactly as he
they were designed to work.

When the designer selects the materials and methods of

transferring power and forces through equipment he works
within the material’s design limits, chemical compatibility,
thermal expansion allowances, fits and tolerances and the
like. When the equipment is taken beyond the abilities of its
design it is operating outside the expected duty and outside
its limits of safe service. The equipment can fail at any time
under those totally unwanted and unplanned conditions.
FEED FORWARD PUBLICATIONS, PO Box 578, BENTLEY, West Australia, 6102 Web: www.feedforward.com.au E-mail: info@feedforward.com.au
Because the authors, publisher and resellers do not know the context in which the information presented in the flyer is to be
used they accept no responsibility for the consequences of using the information contained or implied in any articles.