Deepwater

Pipelines Technology for offshore

oil and gas operations

Also Inside

Accuracy and traceability

of flow measurement

How the floating ball

valve works

Condition monitoring of
heat-transfer pumps

APRIL 2019 • Vol. XXIV, No. 4

www.flowcontrolnetwork.com
 AHR EXPO
PREVIEW
Page 28

FLUID
Density
The effects of
temperature and
pressure

Also Inside

Automating custody transfer

level measurements

Ultrasonic flowmeters for

HVAC monitoring

Performing a storage
tank risk assessment

JANUARY 2019 • Vol. XXV, No. 1

www.flowcontrolnetwork.com

Connect
SOLUTIONS FOR FLUID MOVEMENT, MEASUREMENT & CONTAINMENT

Magazine Like us
Subscribe to our print or digital edition on Facebook

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GF Piping Systems

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• 2 Passive 4-20mA Loop Outputs Standard
• Choice of up to 4 Relays – Dry contact or Solid State
• Optional Two mechanical relay module with four binary
inputs for up to four more sensing points
• Advanced Boolean Relay Logic
• Derived Functions : Ratio, Difference, Sum, % Rejection,
% Recovery
• Onboard Clock and Calendar for Scheduled Events
The 9950 SmartPro Transmitter takes a simple approach to
modularity. Choose from DC powered only or AC/ DC powered
system. The 9950 is ready to run out of the box with its standard
two 40-2omA passive outputs. Add optional relay modules and
binary inputs, and transform your SmartPro in to a two channel
controller. With on board clock/calendar, derived functions,
and advanced relay operation, you have seemingly countless
configurations to meet your process control needs.
Regulating Valve
GF Piping Systems is pleased to introduce the innovative modular
5 series pressure regulating valve (PRV). The modular design allows
users to easily change configurations. The valve can be changed from
a back-pressure valve to a reducing valve by simply changing out the
cartridge. Springs can be added or removed to meet optimum pressure
ranges. In addition, the modular design allows for easy and quick
maintenance for scheduled shutdowns. An online tool is available,
making sizing a breeze. All sizes are molded, which eliminates
inconsistencies found in machined valves. The type 586 is the
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• No re-torqueing needed
• Modular
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• 100% molded design means
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 Remain compliant and minimize risk.

“We help you focus on producing higher-quality

products at a lower cost. To reach this goal, we
provide a global calibration program, standardized
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Calibration Manager

Learn more about our calibration capabilities:

go.endress.com/us/calibration-capabilities
Table of Contents | April 2019 • Vol. XXV, No. 4

Cover Story
10 Creating safe buckling zones
in deepwater pipelines
By Steven Bray, Trelleborg
Rotating buoyancy modules can help manage
and mitigate risks associated with buckling of
high-temperature subsea pipelines.

Features 10
14 The importance of accurate flow
measurement in industrial processes
By Neil Bowman, TUV SUD NEL
Effective measurement systems are contingent upon
understanding the uncertainty and performance
required for a given application.

17 Specifying pipeline ball valves

By Alex Schick and Joe DeMonte, 14 20
Emerson Automation Solutions
Consider components and features when selecting the
correct ball valve for isolation, control, general service
and severe service applications. Departments
4 From the Editor
20 Functionality and seating technology
for floating ball valves 6 News & Notes
By David M. Schmitt, Control-Tech Inc.
A typical floating ball valve seals off the line pressure 8 Application Corner & Quiz Corner
using soft seats.
28 Trade Shows & Events

26 Continuous monitoring of pumps in

heat-transfer systems
30 Featured Products
By Christian Martin, CIRCOR | Allweiler 31 Advertiser Index
Condition monitoring systems provide early leak detection
and allow users to optimize their heat-transfer pumps. 32 FlowControlNetwork.com
Cover: AlexLMX/iStock

Flow Control (ISSN #2641-6735) is published 12 times a year © Endeavor Business Media, 2019. No portion of this publica-
by Endeavor Business Media, 1 Mt. Laurel Avenue, Suite 207,
Birmingham, AL 35242.
tion may be reproduced in any form without written permission
of the publisher. Views expressed by the bylined contributors
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POSTMASTER: Send address changes to: Flow Control, P.O. Box Subscribe/Renew/Change of Address:
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2 | April 2019 Flow Control

 lb/cf

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t/h bbl/h

fact
High flow rates up to 169,000 lbs/h
OPTIMASS 2400 –
technology driven by KROHNE
• Multiple straight tube Coriolis flowmeter in sizes DN100…400/4…16”
• Entrained Gas Management (EGMTM): reliable indication
of gas entrainments, maintaining operation at all times
• Highest safety factor with optional pressure rating 180 bar/2,610 psi,
PED approved secondary containment up to 150 bar/2,175 psi
• NACE compliant with Duplex or Super Duplex as wetted material
• ATEX, IECEx, CSA, FM, NEPSI, CEPAL, MID, OIML

products solutions services

More facts about the OPTIMASS 2400: us.krohne.com/optimass2400


From the Editor
N
ominations are in for our annual
Innovation Awards program, and
I’d like to thank all of you for your
submissions. If you let the deadline slip
by, visit www.flowcontrolnetwork.com/
innovationawards — there still may be
time to submit your new technology or
breakthrough product. We will present
the nominations in our June issue of Flow
Control, as well as online, and readers
will have a chance to vote on the win-
ners. The winners will receive recognition
this fall within a special section featuring
case studies.
In May, the Offshore Technology
Conference (OTC) in Houston offers new
technologies for the oil and gas industry.
I’m looking forward to attending the event
and learning more about your company’s
latest and greatest offerings. Please
feel free to reach out to me to set up an
appointment.
According to Research and Markets in
its Offshore Pipeline Market report, the
offshore pipeline market is expected
to grow from $11.5 billion in 2018 to
$15.8 billion by 2023 at a CAGR of
6.54 percent. The report states that the
transport line segment is expected to
dominate the market with approximately
25,000 kilometers of offshore pipeline
to be added during the forecast period.
EDITORIAL ADVISORY BOARD
Jeff Jennings: Equilibar LLC | Mitch Johnson: JMS Southeast | Gobind Khiani: Fluor Canada Ltd.
Jim Lauria: Mazzei Injector Company | John Merrill, PE: EagleBurgmann Industries
Steve Milford: Endress+Hauser U.S. | Tom O’Banion: Emerson Automation Solutions
David W. Spitzer, PE: Spitzer and Boyes LLC | George Weihrauch: ABB Motors & Mechanical
Andrew Yeghnazar: Blacoh Fluid Control | Jesse Yoder, Ph.D.: Flow Research
4 | April 2019
Theerapong28/iStock
VICE PRESIDENT & GROUP PUBLISHER
MICHAEL C. CHRISTIAN
mchristian@endeavorbusinessmedia.com
EDITOR IN CHIEF
MOLLY ROGERS
mrogers@endeavorbusinessmedia.com
CONTRIBUTING EDITORS
AMY W. RICHARDSON
arichardson@endeavorbusinessmedia.com
MARIE MCBURNETT
mmcburnett@endeavorbusinessmedia.com
GROUP ASSISTANT EDITOR
DANIEL GADDY
dgaddy@endeavorbusinessmedia.com
COLUMNIST
Given the continued focus on offshore DAVID W. SPITZER
ART DIRECTOR
development, Steven Bray with Trelleborg
RYAN CARLSON
explains in this issue’s cover story how
PRODUCTION MANAGER
operators are considering mitigations in AMANDA PORTER
the design phase of pipeline systems aporter@endeavorbusinessmedia.com
to help manage risks associated with DISTRICT MANAGER
buckling of high-temperature subsea JAY HAAS | 281-980-5831
pipelines. Bray says rotating buoyancy jhaas@endeavorbusinessmedia.com
technology offers a solution to prevent ACCOUNT MANAGER
unpredictable lateral buckling. ADDISON PERKINS | 205-463-1774
aperkins@endeavorbusinessmedia.com
We also bring you an article from TUV
NATIONAL ACCOUNTS MANAGER
SUD NEL’s Neil Bowman who discusses the
JIM SEMPLE | 908-963-3008
importance of accurate flow measurement in jsemple@endeavorbusinessmedia.com
process industries, and CIRCOR’s Christian ACCOUNT MANAGER
Martin shares a case study on condition LISA WILLIMAN | 518-322-6691
monitoring of heat-transfer pumps. lwilliman@endeavorbusinessmedia.com
Lastly, you’ll find two articles focused DIGITAL BUSINESS DEVELOPMENT MANAGER
on valves in this issue. Authors with MICHAEL RING | 347-365-0641
mring@endeavorbusinessmedia.com
Emerson talk about how to select the
MARKETING MANAGER
correct ball valve for specific applications,
NICK PHILLIPS
and David Schmitt gives an in-depth dis-
DIGITAL OPERATIONS MANAGER
cussion on how floating ball valves work. MARY BETH ROMANO
Thank you for reading this issue of Flow AUDIENCE DEVELOPMENT MANAGER
Control, and I hope to see you in Houston! ANNA HICKS
SUBSCRIPTION & REPRINT REQUEST
Sincerely, flowcontrol@omeda.com
CORPORATE TEAM
CHIEF EXECUTIVE OFFICER
CHRIS FERRELL
Molly Rogers CHIEF OPERATING OFFICER
mrogers@endeavorbusinessmedia.com PATRICK RAINS
@FlowControl_Mag EXECUTIVE VICE PRESIDENT
SCOTT BIEDA
Flow Control
 Are You Using the
Best Tools for the Job?

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Electromagnetic Meters Mass Flow Meters
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News & Notes
Company news
Saint-Gobain Seals to qualify
its polymer compounds
Saint-Gobain Seals was selected by a U.S.
oil and gas corporation to qualify its
Fluoroloy sealing solutions and polymer
materials to enhance oil recovery for an
ultra-high pressure field in the Gulf of
Mexico, contributing chemical compat-
ibility tests with requirements for 20,000
psi pressure (20K) valve qualification.
Purpose of the testing will assess the
suitability of nonmetallic sealing materials
in specific stimulation hydrofluoric acid
fluid mixtures representative of the com-
position commonly used in the Gulf area.
Carried out by a third-party laboratory,
the complete immersion test campaign
resulted in the confirmation of each of
the four Saint-Gobain Seals’ Fluoroloy
materials meeting the requirements
of NORSOK M-710, edition 3 standard
after hydrofluoric acid fluid exposure up
to 300°F (149°C) temperature.
IndianOil selects Emerson as
automation contractor
Emerson announced it has signed mul-
tiple contracts totaling $12 million with
Indian Oil Corporation Limited to modern-
ize operations and emissions programs
at the company’s refineries. Under the
contracts, Emerson will serve as automa-
tion contractor to help IndianOil meet the
country’s new Bharat Stage VI (BS-VI)
low-sulfur emissions standards, which
take effect in April 2020. The BS-VI
emission standards mandate a maximum
sulfur content of 10 parts-per-million,
which matches best practices set by
Europe, the U.S. and other countries,
and include limits on carbon monoxide,
nitrogen oxides and particulate matter.
The project will upgrade 14 different pro-
cess units, including diesel hydro-treating
units designed to reduce sulfur content
and octane-boosting units either being
installed or augmented with desulfuriza-
tion technologies.
Implico Group names CEO
Tim Hoffmeister takes over the newly cre-
ated position of chief executive officer
6 | April 2019
(CEO) of Implico Group. In addition to
managing the finance and controlling
department, he is now responsible for
the administration and human resources
divisions. Tim Hoffmeister joined the
software and consulting company, which
specializes in the downstream oil and gas
industry, as chief financial officer (CFO)
in September 2018. Since then, he
and fellow managing directors Stephan
Buhre, Thomas Ernst and Torsten Peter
have driven the firm’s realignment and
repositioned its innovation section.
Quorum Software acquires
Coastal Flow
Quorum Software, a Thoma Bravo portfolio
company, announced it has entered into a
definitive agreement to acquire Houston-
based Coastal Flow Measurement Inc., a
family of energy measurement services
and software companies, including its
information services and technologies
subsidiary, Flow-Cal Inc. The acquisition
expands Quorum’s oil and gas software
and services portfolio with a leader in
measurement data management for natu-
ral gas and petroleum liquids.
Endress+Hauser breaks
ground at US Gulf Coast site
Endress+Hauser invests $38.5 million into
a new 112,000-square-foot Gulf Coast
Regional Center Campus. The new site
is in Pearland, Texas’ lower Kirby district,
just outside the Houston area. It will offer
areas for calibration, repair and training,
which will include a new state-of-the-art
PTU (Process Training Unit). The facility will
house teams to support Endress+Hauser’s
products, solutions and services for process
automation, SpectraSensors’ gas analysis
systems for the U.S. and international cus-
tomers and Analytik Jena’s product lines for
laboratory instrumentation. The campus will
include a building and warehouse location
for Endress+Hauser’s partner for sales and
service in the Gulf region, Vector Controls
and Automation Group. Completion is pro-
jected by the end of 2020.
KMC Global’s Controls &
Automation division expands
KMC Global, a group of wholly owned,
autonomous companies — including
PRAB Inc. — announced the expansion
of its Controls & Automation division to
serve outside markets. The technology-
based company provides control panels
for industrial equipment plus automation
and integration with remote and on-site
support capability. KMC Global Controls
& Automation provides a single point of
contact for all controls and automation
needs and offers a variety of services,
including Certified 508A-Listed industri-
al control panels, control panel design,
automation and integration, and remote
and on-site automation.
Komax Systems celebrates
45 years
Celebrating its 45th anniversary, Komax
Systems Inc. has provided solutions for
demanding and difficult inline mixing and
heat transfer applications worldwide and
has applied knowledge to a technical base
of more than 100,000 installations across
the globe. The company has also devel-
oped technologies resulting in more than
40 patents (with more pending) for inline
static mixing and heat transfer. Komax
Systems Inc. has been verified by the
Pressure Equipment Directive (PED) and
is certified by the ISO Series of Standards.
Hawk Measurement receives
approval certification with its
Centurion Guided Radar
Hawk Measurement Systems was awarded
explosion-proof, flame-proof and dust-igni-
tion-proof certification by FM Approvals
for FM, FM Canada and ATEX standards.
The company’s Centurion Guided Radar is
a continuous level measurement instru-
ment that uses guided-wave technology
that sends a radar pulse down a probe
to measure either liquids, solids or a low
dielectric to high dielectric interface level.
The pulse hits the surface and is reflected
back up the probe to the sensor, where the
transit time is translated into a distance
using time of fight and time expansion. FC
Send news and events for consideration
to Molly Rogers at mrogers@
endeavorbusinessmedia.com.
Flow Control
 June 25-27

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 Application Corner
By David W. Spitzer
Natural gas flow measurement:
The heat is on
T
he North American Energy Standards
Board (NAESB) description of a typi-
cal natural gas composition was dis-
cussed in last month’s column. However, the
actual natural gas composition at a given
location may be significantly different than
typical, as suggested by ranges of compo-
sitions provided by NAESB. Compositions
vary with location, but the proliferation of
shale gas production in North America,
among other discoveries, has exasperated
the situation. This occurrence begs the
question of how different natural gas com-
positions can affect the measurement of
the flow of natural gas — both personally
(as a customer) and professionally. Let’s
examine the personal side first.
This question is of interest personally
because many or most of us cook and
heat our homes with natural gas. Natural
gas is delivered to customers at a nominal
pressure set and controlled by the local
gas company. Natural gas consumption
in most houses and apartments is typi-
cally measured using a positive displace-
ment diaphragm flowmeter designed and
approved for natural gas custody transfer
service. These flowmeters will measure the
volume of natural gas accurately when the
nominal natural gas pressure is maintained
within tolerances and its temperature
remains within a specified range.
8 | April 2019
However, varying composition can and
will affect the heating value of a given
volume of natural gas. Therefore, the
heating value of actual natural gas at a
given location could be different from a
typical NAESB natural gas heating value
by as much as a few percent. A higher
(lower) heating value than typical would
deliver more (less) thermal energy to
the user in a given volume — decreas-
ing (increasing) billing revenue for the
same amount of thermal energy deliv-
ered. Extreme variations could potentially
adversely affect combustion. To ensure
that the natural gas provided to the
customer contains the proper amount
of energy per unit volume, natural gas
companies typically monitor the heating
value of their natural gas. FC
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 measurement,
instrumentation and process control. He
can be reached at 845-623-1830 or via
spitzerandboyes.com.
Flow Control
 Quiz Corner What is the proper tap location for an orifice plate flowmeter?

A. 1 inch upstream and 1 inch downstream of the orifice plate B. 0 diameters upstream and 0 diameters downstream of the orifice plate
C. 1 diameter upstream and 0.5 diameter downstream of the orifice plate D. 8 diameters upstream and 2.5 diameters downstream of the orifice plate

A
ny of these tap locations could be correct —
depending upon the application and its design.
The mechanical location of flange taps (Answer
A) and corner taps (Answer B) is typically maintained by
purchasing special flanges that are predrilled to accu-
rately locate these taps relative to the orifice plate.
Radius taps (Answer C) and full flow taps (Answer D)
upstream and at the vena contracta, determined by orifice
geometry, downstream.
Additional complicating factors
Selection between flange/corner taps and pipe taps is typi-
cally related to cost and/or the ability to accurately locate
pipe taps in small lines. Selection between flange taps
xijian/iStock

are typically located in the pipe itself. Vena contracta and corner taps is largely determined by personal and/or
taps (not included as an answer) are located 1 diameter geographic preference. FC

www.flowcontrolnetwork.com April 2019 | 9

Cover Story: Oil & Gas

Creating safe buckling zones

in deepwater pipelines
Rotating buoyancy modules can help manage and mitigate risks
associated with buckling of high-temperature subsea pipelines.
By Steven Bray, Trelleborg

D
eepwater pipeline systems are
designed to operate in harsh sub-
sea environments — deep below
the ocean’s surface on the cold ocean floor
made up of soil and sand and teeming with
marine life. In these turbulent waters, pipe-
lines are exposed to changes in pressure
and temperature. As the oil and gas industry
moves further offshore and into increasingly
hostile and more remote places, modern
field developers are requiring flowline designs
that are longer with larger diameters, lighter
and run at higher temperatures.
Dynamic subsea
environments
Traditionally, operators spend a great deal
of resources designing, manufacturing
High-temperature subsea pipelines require special
mitigations to prevent unpredictable lateral buckling
fatigue cycles during operation and shutdown events.
and installing pipeline systems to ensure pipeline, a phenomenon called lateral
they are fit for service. Care is taken to buckling occurs.
verify their long-term integrity and that
operational loads do not exceed extreme Damaging effects
design parameters for the life of a project. of buckling
One challenge that operators are taking Buckling typically occurs during startup
into consideration in the design phase is and shutdown sequences as thermal fluc-
the increasingly widespread buildup of axial tuations cause pipelines to expand and
forces along the pipeline due to tempera- contract, potentially resulting in down-
ture and pressure differences. Coupled time and unexpected costly shutdowns.
with the influence of soil on the seabed, Left unchecked, buckling can cause local
which can restrict free movement of the axial strains severe enough for welds to

10 | April 2019 Flow Control


Figure 1. Rotating buoyancy
generates repeatable and
predictable pipeline behavior.
All images courtesy of
Trelleborg Offshore
fracture, the entire pipeline to collapse
or even full-bore rupture.
High-temperature subsea pipelines
require special mitigations to prevent
unpredictable lateral buckling fatigue
cycles during operation and shutdown
events. Almost all deepwater subsea flow-
lines use mitigation devices to ensure safe
lateral buckling, and one of the commonly
used methods is attaching fixed buoyancy
modules to sections of the pipeline.
In certain offshore conditions, lateral
movement of traditional fixed buoyancy
modules can cause soil compaction,
increased lateral soil resistance and
the formation of berms. Post-production
subsea surveys and engineering evalu-
ations show these berms may actually
www.flowcontrolnetwork.com
Figure 2. (Right) Traditional
nonrotating cylindrical buoyancy module
Figure 3. (Below) Side view of rotating
buoyancy modules engineered to roll
on the seafloor, reducing lateral friction
and berm creation
further restrict lateral movement, caus-
ing secondary regions of high stress.
This further increases the risk of lateral
pipeline buckling in other sections of the
pipeline and affect fatigue life.
Predictable pipeline behavior
Deepwater pipeline systems are often
required to be held in specific
geometric configurations
subsea to prevent over-
use of the system.
Traditional nonrotat-
ing cylindrical buoy-
ancy modules are
installed to reduce
weight and friction
while promoting con-
trolled bending on
pipelines. As previously
mentioned, traditional
fixed buoyancy modules, in
certain conditions, displace sea-
bed material, creating ridges or berms
of earth on the seafloor, which can start
to restrict lateral movement of the pipe-
line and the buoyancy modules, leading
to buckling.
Rotating buoyancy technology can
solve this problem while increasing the
robustness and safety of the system.
It represents a step change in the way
risks associated with buckling of high-
temperature pipelines are managed and
effectively mitigated. The advanced solu-
tion is engineered to reduce lateral friction
and berm creation, thereby generating
repeatable and predictable pipeline
behavior. In addition, the rotating
buoyancy design reduces
the number of modules
needed along the pipe-
line, significantly low-
ering overall project
costs for operators.
Testing
information
The ability of advanced
software analysis to pro-
duce high-performance,
robust and dependable solu-
tions is revolutionizing deepwater
drilling and production. By increasing the
performance of products before they
even enter the water, software analysis
is able to provide the solutions needed
to combat the increasing harsh envi-
ronments presented by the offshore
world, virtually.
April 2019 | 11
 Figure 4. Subsea view of
rotating buoyancy modules
#167
n n
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12 | April 2019
COMMERCIAL LAUNDRIES
n AUTOMOTIVE PLANTS
Software analysis is able
to provide the solutions
needed to combat the
harsh environments
presented by the offshore
world, virtually.
For rotating buoyancy technology, both
small-scale and large-scale tests can
be performed using prototype fixed and
rotating buoyancy modules. By testing
both options, operators can compare
the two mitigation methods and validate
performance with mathematical modeling
techniques. The testing simulates each
system’s in-service conditions, including
pipeline weight, soil properties, soil inter-
action and pipeline travel.
Conclusion
n TANNERIES
Operating in today’s globalized markets
requires a long-term approach with solu-
tions that protect people, the environment
and a customer’s investment. Forward-
thinking companies are committed to
improving the functionality of their products
and solutions to provide wide-ranging ben-
efits to meet and exceed customer needs.
As the search for new oil deposits goes
further offshore and deeper in the ocean,
new challenges will emerge and new solu-
tions will materialize. Uncertainty exists
everywhere, and the unpredictable nature of
lateral buckling is an unstable phenomenon,
yet it can be managed with innovative solu-
tions like rotating buoyancy modules. FC
Steven Bray is the oil and gas business
manager with Trelleborg’s offshore
operation.
Flow Control
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Features: Flow Measurement
The importance of accurate flow
measurement in industrial processes
Effective measurement systems are contingent upon
understanding the uncertainty and performance
required for a given application.
By Neil Bowman, TUV SUD NEL
T
he ability to accurately under-
stand, control and monitor indus-
trial processes is pivotal to the
successful, commercially viable opera-
tion of plants and processes in every
industrial sector. Despite this, instru-
mentation and flow measurement are
not always given the level of resource
and investment that they deserve, and
measurement in general is not always
well understood.
Many factors can affect the perfor-
mance of a measurement system. Some
of these are common to almost any flow
measurement system, such as the cor-
rect installation of the instrument with
appropriate flow conditioning; calibration,
which is suitable for the operating environ-
ment of the meter; appropriate second-
ary instrumentation; and fluid properties
characterization. However, there can also
be a number of factors that are highly
application-specific, such as the pres-
ence of contamination or additional
phases within the flow; contaminants or
solid particulates that cause mechanical
wear, erosion, deposition or corrosion;
or any number of challenging operating
14 | April 2019
environments that can adversely affect
measurement performance.
Factors that adversely affect or under-
mine measurement performance are
often particularly poorly understood or
ignored entirely. However, this can be
a mistake, as the relatively little work
required to develop and maintain effec-
tive measurement systems can reap sub-
stantial benefits.
When operating a process that relies
on measurement systems for the pur-
poses of process control, monitoring
or safety, the ability to characterize the
accuracy of the measurement system is a
critical means of providing confidence in
its performance. This requires an under-
standing of measurement uncertainty,
traceability and calibration, as well as a
management system that incorporates a
measurement policy or philosophy and a
maintenance schedule.
Consider the pharmaceuticals industry,
for example, where complex multistage
chemical processes are required to pro-
duce lifesaving products for medical appli-
cations. Flowmeters are used to control
the mixing of quantities at critical stages
surasak petchang/iStock
as well as the sizing, coloring and coat-
ing of pills, to name a few applications.
Turbine, ultrasonic and Coriolis flowmeters
are all popular options; however, precise
timing and accuracy are critical to ensure
repeatable, high-quality output. In these
applications, quality control is literally a
matter of life or death. Understanding the
accuracy of key measurements is critical
to ensuring consistent product quality.
Another example of the importance of
accurate measurement can be found in
the food and beverage industry. In most
countries, manufacture and sale of
alcoholic beverages must be recorded
for legal and taxation purposes. Such
measurements are essentially similar
to the custody transfer measurements
undertaken in the oil and gas industry.
Given the quantity of beer, wine and
spirits sold across the globe, this rep-
resents enormous taxation revenue for
alcohol-producing nations. According to
the BBC, the U.K. exported 1.2 billion
bottles of Scotch whisky in 2017. This
equated to approximately £4.36 billion
in sales. A measurement uncertainty of
0.5 percent on volume across the industry
Flow Control
would result in a financial exposure of
around £21.8 million. This is obviously a
highly simplistic example, but it illustrates
the potential impact of mismeasurement.
There are endless applications across all
industrial sectors where flow measure-
ment has a similarly critical role to play.
To achieve the accuracy that is so criti-
cal to trade and commerce, most countries
have a dedicated regulatory framework that
supports national measurement infrastruc-
ture designed to facilitate and regulate good
measurement practice. In the U.K., this
system is officially known as the National
Measurement System (NMS), which is
delivered through the U.K.’s Department
for Business, Energy & Industrial Strategy
(BEIS). To support and develop a national
measurement infrastructure in the U.K.,
BEIS allocates £65 million funding.
A fundamental feature to accurate
measurement is traceability. Traceability
plays a vital role in national measurement
infrastructure; without it, accurate mea-
surement and confidence in a measure-
ment system is impossible to achieve.
Traceability requires that it must be pos-
sible to trace a measurement device,
normally through calibration, back to the
national standard. Without this, it is impos-
sible to effectively characterize the uncer-
tainty of a given measurement system.
As we move up the traceability chain
toward a given measurement standard,
the uncertainty in measurement is
reduced; however, to achieve low uncer-
tainty, it is usually necessary to invest
Figure 1. Traceability pyramid
Figures courtesy of TUV SUD NEL
www.flowcontrolnetwork.com
more money in the system in terms of
increased capital and maintenance costs.
This is important to consider, as the most
accurate system is not always the correct
solution for a given application. Owing to
the cost penalty associated with achiev-
ing and maintaining low uncertainty, the
requirements for a given application need
to be considered prior to system design
and component selection.
Despite the work invested in maintain-
ing and regulating the NMS, it is occa-
sionally found — when visiting or auditing
plants and factories — that instruments
are not installed or operated in accor-
dance with the appropriate standard or,
in some instances, no longer traceable to
the appropriate standard. Furthermore,
it is not uncommon to find flowmeters in
service where the operator has no record
of when the device was calibrated and
no planned maintenance for the system.
A common finding when visiting plants
and production environments is that they
are often not taking full advantage of the
available technology. In recent years,
measurement technology has advanced
substantially — principally owing to the
development of advanced electronics and
diagnostics, wireless communications and
powerful data processing. This can present
the ability to monitor system health and
provide insight into a process and its per-
formance. It can be an extremely powerful
tool in the continual drive for improvement
and process optimization. In many cases,
this has left legacy measurement systems
behind; however, occasionally, it has been
found that the technology is already in
place but not fully exploited.
The following is an example from a
spirits bottling plant that highlights such
a situation. During tanker offloading
operations, it was observed that the
plant had purchased an advanced (and
expensive) Coriolis flowmeter as a means
to meter incoming product. Meanwhile in
the control room, a small team was tak-
ing manual samples and using hydrom-
eters to measure the density, which were
written on paper and then typed into a
spreadsheet as a means of evaluating the
ABV (alcohol by volume) of the incoming
Figure 2. Traceability chain
product. One of the advantages of Coriolis
flowmeters is that they directly measure
both mass flow rate and fluid density at
the same time. When asked why they
didn’t use the density output from the
Coriolis flowmeter to continuously mea-
sure the ABV of the incoming product,
they were unaware that Coriolis meters
had this capability. Whether this replaces
archaic processes or simply augments
them with modern and robust techniques,
this is a powerful and potentially valuable
capability that is underutilized.
So why don’t companies invest more in
such powerful diagnostic tools? A key fac-
tor is the apparent lack of impact occurring
from high measurement uncertainty. If we
consider the oil and gas and petrochemi-
cal industries, the story is usually very
different. These organizations typically
have dedicated metering departments.
The reason for this is that hydrocarbon-
based products are high value, thus there
is a direct fiscal impact in the uncertainty
associated with their flow measurements.
When looking at hydrocarbon systems, it
is easy to see how small uncertainties can
lead to large financial exposure — even
over short timescales.
Another key factor is that these indus-
tries are regulated much more tightly than
other industries due to the fiscal value of
the metered product. The same degree
April 2019 | 15
of stringent regulation does not often
apply to flow measurements in the con-
text of industrial or plant environments
compared to the oil and gas sector, and
companies within the food and beverage,
power and chemical industries will rarely
undertake full flow measurement audits.
In some industries, there is a degree
of inertia regarding the adoption of new
processes or technology and often under-
standably so. Many processes that have
been in operation for years — and even
ones that already incorporate flow mea-
surement — work fine as they are, so
there’s no need to fix them. Nevertheless,
instrumentation is often underutilized.
Regardless of the industry, a key ques-
tion is, do you have an understanding
of the uncertainty that you require for
your application and the uncertainty
of the given measurement system?
Furthermore, how does your measure-
ment system perform over time, how
frequently do you calibrate, and do you
have any past performance data that
would allow you to evaluate the optimal
calibration period? Fundamentally, are
these factored into your quality system?
Conclusion
Traceability and good measurement prac-
tice are critical to achieving accurate,
repeatable flow measurement. However,
selecting the appropriate solution is con-
tingent upon understanding the uncer-
tainty and performance required for a
given application, which requires a fun-
damental understanding of metrology as
well as the process to which it is applied.
Getting this right has the potential to
yield substantial commercial benefits
through enhanced efficiency and control.
Furthermore, given the sophistication and
capability of modern flow measurement
technology, such systems can do far more
than simply measure flow rate; they can
also provide powerful diagnostic capa-
bility that can yield insight into both the
performance of the measurement system
and the process in which it operates. FC
Neil Bowman is a Chartered
Mechanical Engineer, provid-
ing fluid mechanics and flow
measurement consultancy
services to a range of industry sectors. He
frequently delivers NEL’s Principles and
Practice Flow Measurement course and
has experience with a range of flow mea-
surement technologies, both from a theo-
retical and practical perspective, and in
challenging and nonstandard applications.
He is a project engineer at TÜV SÜD NEL,
a global centre of excellence for flow mea-
surement and fluid flow systems and the
U.K.’s National Measurement Institute for
Flow Measurement. TÜV SÜD NEL is part
of the TÜV SÜD Group.

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16 | April 2019 Flow Control

Features: Valves
Specifying pipeline ball valves
Consider components and features when selecting the
correct ball valve for isolation, control, general service
and severe service applications.
By Alex Schick and Joe DeMonte, Emerson Automation Solutions
P
ipeline ball valves (as shown in Figure
1) are routinely misapplied in the
field. For example, isolation valves
are often used in control applications, lead-
ing to poor flow control and possible valve
damage. This is because their seal and
packing designs are typically unsuited for
throttling applications.
In most cases, control applications
have relatively high pressure drops across
the valve that can lead to increased
noise, cavitation and vibration. Without
adequate trim, a control valve is unsuited
for the application and can be damaged
by noise, cavitation and vibration caused
by these pressure drops. Accurate con-
trollability greatly depends on the ball
shaft connection, adequate shaft guid-
ing, packing design and actuator style.
Isolation valves do not have the required
features for these types of throttling
applications.
On the other hand, control valves should
not be used in isolation applications.
Control valves are designed to have inher-
ent leakage as specified by ANSI/FCI 70-2,
which typically makes them unsuited for
isolation applications. Most control valves
are also not fire-tested like isolation valves.
And, flow coefficient (Cv) is calculated dif-
ferently for isolation and control valves.
www.flowcontrolnetwork.com
Inside isolation valves
On pipelines, isolation valves are often
used to isolate process fluid from moving
downstream when a nearby control valve
is closed. For every control valve, there
should be an isolation valve upstream
and downstream if applicable.
Isolation valves use a nonmechanically
retained seal to leverage seal injection
ports for tight shutoff. These valves
have O-ring style packing (see Figure
2), ideal for low-cycling applications, and
the packing includes a fire-safe gasket.
These valves can either be manually
operated or automatically operated by
an actuator.
The ball/shaft connection is typically
pinned or has a double-D style design.
Figure 1. (Above) Proper
selection of pipeline ball
valves, such as these
Fisher Model V260A
severe service valves, can
provide appropriate control
and reduce maintenance.
All images courtesy
of Emerson Automation
Solutions
Figure 2. (Left) Isolation
valves have several
features designed for
bubble-tight shutoff and
fire safety.
The actuator/valve shaft connection is
keyed. These connections have inherent
lost motion in the design, and the valve
can perform poorly when throttling.
When selecting an isolation valve, look for:
• Seal injection ports for tight shutoff
• Suitability for buried service applications
• O-ring packing construction
• Suitability for manual operation
• Compliance with API 6D
While isolation valves are good for low-
cycling applications, they are not ideal
for dynamic performance. Isolation valves
are not designed to be installed at angles
between 0 and 90 degrees like control
valves and should only be fully closed or
wide open.
April 2019 | 17

Figure 3. A general service control valve, such
as this Fisher Model V270, is designed for line
pressures of up to 1480 psi.
General service
control valves
General service applications do not
require noise attenuation, cavitation pro-
tection or tight control; therefore, general
service valves do not have splined shafts
or attenuators but are still equipped for
dynamic applications. Severe service
applications are those in which exces-
sive noise or cavitation is expected.
A general service, trunnion-mounted
and full-bore pipeline ball valve (as shown
in Figure 3) can be used in both con-
trol and isolation applications. It has the
mechanically retained seals necessary
for throttling without the risk of seal fail-
ure. Taking a high pressure drop across
the valve while throttling at low degrees
of travel can cause nonmechanically
retained seals to be sucked out of the car-
rier, resulting in damage to the seal and
preventing the valve from being shut off.
Other features include live-loaded pack-
ing and a robust drive train designed to
absorb energy properly at mid-travel. As the
control valve throttles, it absorbs energy,
creating side-loading on the valve shaft.
The live-loaded packing guides the valve
shaft under these conditions. Mechanically
retained seals prevent damage to the trim
during pressure drops often experienced
when flow is throttled down significantly.
When selecting a general service con-
trol valve, look for:
18 | April 2019
• Design compliance with both B16.34 allows the valve to not take the entire
and API 6D pressure drop at once. Aerodome-style
• Mechanically retained seal inserts trim can be used to keep the noise level
• Live-loaded packing down to a reasonable level. These trims
can be customized for different startup
A general service control valve can be cases and for full capacity to fit the
used in almost any application that does desired application.
not require noise reduction and extreme When selecting a severe service ball
precision. However, a double-D or pinned valve, look for:
ball shaft connection does not provide • Anti-cavitation trim
the highest performance because general • Splined-shaft connections
service applications generally do not have • Fast-stroking capabilities
stringent throttling requirements. • Adaptable product platform for
special constructions
Severe service valves
Typical severe service applications require Pipeline applications
high-performance actuation. This could Ball valves can be used in the following
be needed for fast stroking speeds or applications:
higher cycles. Proper O-rings, actuator • Within a gate station
accessories and other valve components • As a worker/monitor valve
and features need to be considered when • To provide over-pressure protection
selecting valves for severe service. To • As a pump station pressure-control valve
greatly reduce lost motion, a severe • Within a compressor station
service, trunnion-mounted and full-bore • To provide anti-surge protection
pipeline ball valve (as shown in Figure
4) has splined ball-to-shaft and shaft-
to-actuator connections.
Cavitation can be a problem in severe
service applications. When pipeline fluid
flows through a fixed restriction like a con-
trol valve, the pressure drops. Depending
on the severity of the pressure drop and
the fluid properties associated with the
process, this can cause cavitation.
Cavitation occurs when the pressure
at the vena contracta falls below the
vapor pressure of the process and then
recovers downstream. Cavitation can
lead to extensive damage
to valve bodies and trim.
In gas service, noise and
vibration can be gener-
ated by high pressure
drops across the control
valve; therefore, dealing
with these sources of cavi-
tation and noise is essential
in preventing damage to the
valve in severe service applications.
Pipeline ball valves can be supplied Figure 4. A severe service, anti-surge valve,
with various types of anti-cavitation and such as this Fisher Model V260A, has a
rugged actuator and other features for fast
noise-protection trims to stage the pres- stroke, long life and high performance in
sure drops and prevent cavitation. This demanding applications.
Flow Control
 As pipeline gas travels from higher- Alex Schick is a product Joe DeMonte supports
pressure pipelines to lower-pressure pipe- marketing manager for Emerson’s flow control
lines in cities, the gas passes through a Fisher Rotary Valves at products as the global mid-
gate station with worker and/or monitor Emerson. He is a gradu- stream oil and gas and LNG
valves to reduce pressure. The worker ate of the University of Iowa with a B.S. industry manager. He is also Emerson’s
valve handles the pressure drop and in Engineering and an MBA. Schick has subject-matter expert on anti-surge valves.
maintains a lower pressure downstream. been with Emerson in Marshalltown, Iowa, DeMonte received a B.S. and M.S. in engi-
This considerable pressure drop gener- for five years. neering from the University of Iowa.
ates noise and vibration.
Typically, noise attenuation trim is
required along with features that provide
tight throttling control. The monitor acts
as a backup to the worker; if something
happens, it takes over and controls the
pressure downstream. While the monitor
valve may require less throttling control,
it may still be needed to perform like a
control valve.
An over-pressure protection, or super
monitor valve, often performs as a gen-
eral service valve. It can be upstream of
the worker and monitor or at the inlet
of a gate station or compressor station.
If the station needs to shut down, this
valve will close, so throttling control and
shutoff are important for this application.
A pump station pressure-control valve
minimizes the pressure drop when fully
open. These valves need to be able to
handle transient conditions with higher pres-
sure drops — often occurring during startup
— that could lead to periods of cavitation.
Compressor stations may be placed
every 50 to 100 miles on a pipeline to
help boost pressure. Typically, an anti-surge
control valve is used to prevent the com-
pressor from experiencing surge, which can
cause costly damage to the equipment.

Conclusion
Proper ball valve selection will result in
more uptime and better performance,
and it will prevent “sucking out” of seals
and damage to the drive train. The cor-
rect valve will provide appropriate control
and reduce required valve maintenance.
Users should check published specifi-
cations to ensure the valve meets the
aforementioned requirements. The valve
manufacturer should be able to provide
technical assistance and demonstrate
that the valve being considered has been
used in similar pipeline applications. FC

www.flowcontrolnetwork.com April 2019 | 19

Features: Valves
Functionality and seating technology
for floating ball valves
A typical floating ball valve seals off the
line pressure using soft seats.
By David M. Schmitt, Control-Tech Inc.
A
floating ball valve is a ball valve
with an unsupported ball — other
than the two seats it rests on —
so that the ball moves in the valve cavity
to help seal off the line pressure.
The key to ball valve performance is
the sealing design, regardless of whether
the seats are made of metal, plastic or
other material. Another important function
of ball valve performance is the stem seal
design. A typical floating ball valve seals
off the line pressure using soft seats such
as PTFE (a plastic material called polytet-
rafluoroethylene and otherwise known as
Teflon) or TFM (a modified version of PTFE
and also known as TFM 1600). TFM has
a slight pressure/temperature advantage
over PTFE. Both known for their fairly high
temperature and pressure capabilities,
PTFE and TFM are ideal choices for seat
material. However, neither has a good
memory; once the seat is compressed
or misshaped in any way, the material
will not return to its exact original shape.
How the floating
ball valve works
Pressure on a closed valve acts not only
on the upstream side of the ball, but also
on the back side of the upstream seat.
The outcome of this force pushes the ball
and the upstream seat in the direction
of the downstream seat (see Figure 1).
This force can result in both elastic defor-
mation and plastic deformation of the
downstream seat. The onset of extreme
plastic deformation results in the limita-
tions of the valve seats.
Elastic deformation is the intended tem-
porary deformation engineered in the seat
20 | April 2019
design that uses the stored energy in the
design to temporarily change its shape to
improve sealing performance while under
pressure and temperature swings.
Plastic deformation is the permanent
deformation of the seat due to compres-
sion or extreme pressures and tempera-
tures. This is sometimes referred to as
“cold flow.” Again, this defines the limi-
tations of the seat design and material.
Seating technology
There are two different types of seating
technology used in floating ball valve
designs: jam seat and flexible seat, which
is also referred to as an energized seat.
Many of the early commercial ball valve
designs, as well as some used today,
depend on the jam seat design. This type
of sealing is created from using excess
material in the seat design, thereby 2-inch ANSI 300-pound flanged
automated ball valves
“jamming” the ball (during assembly)
All images courtesy
slightly into the seat, which causes the
of David M. Schmitt
seat to be compressed against the ball
and inside body wall (see Figure 2). The
compression, or preset of the seat, is
thereby compromising the seat due to
plastic deformation. While this plastic
deformation is slight, the compression
of the seat is needed for tight sealing.
This allows sealing in low-pressure appli-
cations, and as the pressure increases,
the ball is forced into the downstream
seat, causing a tighter seal.
Also with this type of design, the seat
has already formed some slight plas-
tic deformation due to compression,
so if upstream pressure is substantially
increased, it will cause more plastic defor-
mation because the ball pushes harder into
Flow Control
 Figure 1. (Left) Pressure
pushes the ball and the
upstream seat in the direction
of the downstream seat.

Figure 2. (Right) Jam seat

before and after preset

www.flowcontrolnetwork.com April 2019 | 21

the downstream seat. This is not a problem
as long as the pressure remains at a high
level, but if the pressure were to decrease,
leakage would most likely occur because
the seat would not return to its original
shape — meaning that it has “cold flowed.”
A jam seat has no pressure compensation.
Figure 3. Flexible seat before preset
Another problem associated with jam
seats is temperature swings. Thermal
expansion is the general increase of volume
of a material as it is heated. It is usually
expressed as a fractional change in length
or in volume per unit temperature change.
A coefficient is applied to a given material
to compare the rate of thermal expansion
from one material to another. This rate is
known as the material’s coefficient of ther-
mal expansion. Normally, linear expansion
coefficients are given for solids, while volume
coefficients are given for liquids and gases.
In the case of increasing temperatures
in a ball valve, the steel body and ball
expand; however, the PTFE or TFM seats
expand at a considerably higher rate —
possibly as much as eight times the rate
of the metal surrounding them. If the tem-
perature change is high enough, the jam
seat will generate even more plastic defor-
mation beyond its original shape. Should
the valve then become cooled, shrinkage
of the additionally deformed seat would
most likely cause leakage. A jam seat also
has no thermal compensation.
When subject to wear, the sacrificial ele-
ment in ball valves are the seats. The seats
are a reasonably priced replacement; how-
ever, under high cycle conditions, jam seats
wear out fairly quickly depending on shutoff
pressure and valve size. A jam seat also
has no wear compensation.
All plastics have a zone of elastic
behavior and a zone of plastic behavior.
The object is to capitalize on the zone of
elastic behavior to use the stored energy,
much like a diving board.
There are many different designs of the
energized seat. Again, the energized seat
has a way of using the stored energy engi-
neered in the design to compensate for
changes in pressure, thermal compensa-
tion and wear by taking advantage of the
elastic deformation built into the design. For
example, a popular design used to achieve
built-in energy in the seat is to shape the
internal diameter of the seat so it is flex-
ible. Along with this design, a flexure zone
is included between the valve body and the

NSF/ANSI 61 outside edge of the seat (see Figure 3). An

initial preset, which takes place during final

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applied to the seat to cause the seat to
bend into the flexure zone, thus storing elas-
tic energy. This design takes advantage of
the elastic deformation built into the design,
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movement shown above (in comparison of
the size of the seat shown) is exaggerated for
illustration purposes. Depending on the size
of the valve and the amount of upstream
pressure, the movement is actually miniscule.

22 | April 2019 Flow Control

therefore decreasing the chance of plastic
deformation due to increases in pressure,
thermal expansion and wear. As long as
there is some clearance between the seat
and the body in the flexure zone, the seat
will flex rather than cold flow.
The jam seat design also uses a preset,
but in that case, there is no flexure zone
built into the design and uses only plastic
deformation to seal.
Sealing within a floating
ball valve
With both the jam seat design and the
flexible seat design, in a new valve,
upstream sealing will occur as long as
upstream pressure does not move the ball
past the effective preset. As upstream
pressure increases, it forces the ball and
the upstream seat to move in the direc-
tion of the downstream seat, causing the
ball to press tighter against the down-
stream seat, which gives the valve a tight
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shutoff. When this happens, a gap will upstream pressure, even at lower pres-
form between the valve body and back of sures, to enter the valve cavity.
the upstream seat. This allows upstream To help assist and ensure the upstream
pressure to enter the valve cavity, which pressure enters the cavity to balance the
is exactly what is intended (see Figure 4). pressure, radial grooves are slotted into
There are several advantages in equal- the outer edge of the seats (see Figure 5).
izing the upstream pressure with the Radial grooves only effect sealing of the
pressure in the cavity; it reduces fric-
tion, minimizes seat damage and provides
much lower operating torque. If the valve
is automated, it would result in a smaller
actuator and lower costs.
Floating ball valves are downstream
sealing devices. The valve has two seats
merely to make it bidirectional. This means,
which either way it is installed in the pipe,
both sides work the same. However, as
previously mentioned, upstream sealing
will occur as long as the upstream pressure
does not move the ball past the effective
preset on a new valve. But, as the valve
Figure 5. Radial
wears, the effective preset of the design grooves to ensure
is lowered, thus making it easier for the pressure balance
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April 2019 | 23
 Figure 6. (Left)
To prevent cavity
pressure increase,
place a vent hole
pointing upstream
when the valve
is in the closed
position. This,
however, makes
the valve
unidirectional.

Figure 7. (Right)
Self-relieving seats

upstream seat because the downstream
seat is forced by the ball into the internal
valve body where sealing occurs on the
back side of the downstream seat. Radial
grooves do not make the valve unidirec-
tional. The valve remains bidirectional
because both seats are identical; the
forces that occur inside the valve are also
identical, keeping the valve bidirectional.
Thermal fluid expansion
In a floating ball valve, the cavity created
between the two seats is an absolute ideal
containment vessel for pressure increases.
Surprisingly, there is a magnitude of pres-
sure rise associated with temperature
increases of a trapped incompressible
due to thermal expansion. Ordinary water
trapped without any air will increase in
pressure about 100 psi for every degree
in Fahrenheit of temperature increase.
For example, 10˚F will raise the pressure
approximately 1000 psi. And, the pressure/
temperature relationship of most common
liquids is approximately 90 to 110 psi per
degree Fahrenheit. In fact, ANSI B16.34
Paragraph 2.3.3 “Thermal Fluid Expansion”
states: “It is the responsibility of the user to
provide or require to be provided, means in
design, installation or operation procedure
to assure that pressure in the valve will not
exceed that allowed by this standard for the
attained temperature.”
There are a couple ways ball valve manu-
facturers address the problem of increased
cavity pressure due to thermal fluid expan-
sion. While the valve is in the open position,
any pressure in the cavity created by the
ball, seats and body can easily be vented

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24 | April 2019 Flow Control

by drilling a small hole from the top of the
stem slot to the ball flow path. Cavity pres-
sure easily escapes from the cavity through
the hole in the stem slot and pushes out
the downstream side of the valve. However,
it is much more difficult to vent the cavity
while the ball is in the closed position. One
way to accomplish this is to drill another
hole in the ball so that when the valve is in
the closed position, the vent hole is pointed
upstream, thereby venting the captured
media upstream while keeping the valve
from leaking downstream (see Figure 6).
While the vent hole is certainly a suitable
way to prevent cavity pressure from building,
it also makes the valve unidirectional. This
is the only way that a valve using a jam seat
design is capable of venting cavity pressure.
A valve using an energized seat design
has the capability of the seat to flex back
and forth. Cavity pressure relief will take
the path of least resistance. The increased
cavity pressure, now greater than the
upstream pressure, will force the upstream
seat to move away from the ball and flex
or bend toward the upstream pressure
side and vent upstream. It only takes a
small amount of pressure relief for the
cavity pressure to return to normal. Some
manufacturers call this a “burping” effect
of the upstream seat, and some refer to it
as “seeping” relief. Regardless, these are
self-relieving seats (see Figure 7).
With that said, even the manufacturers
who design their valves with self-relieving
seats recommend that for high volatility duty,
such as liquid chlorine, or cryogenic service,
where the fluid or gas is known to possess
rapid thermal expansion characteristics, it
is recommended that direct discharge relief
is provided using an upstream vented ball.
Conclusion
With many manufacturers in today’s grow-
ing market of floating ball valves, the
floating ball valve should not be treated
as a commodity. Serious consideration
should be given to determine which valve
is best suited for the application. FC
David M. Schmitt is an
outside sales representa-
tive for Control-Tech Inc.,
an industrial valve and
instrumentation distributor/representative
that specializes in pressure, temperature,
level and flow instrumentation as well as
valves, valve automation and controls.
Schmitt earned a B.S. in management with
a minor in marketing from Missouri State
University. He has 35 years of experience
in industrial distribution of various brands of
ball valves. Schmitt attributes much of his
knowledge of ball valves to Joe Wright while
working at Neles-Jamesbury Corporation.
Schmitt can be reached at valveman2u@
aol.com. For more information, visit Control-
TechInc.com.

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www.flowcontrolnetwork.com April 2019 | 25

Features: Pumps

Case study: Continuous monitoring

of pumps in heat-transfer systems
Condition monitoring systems provide early leak detection
and allow users to optimize their heat-transfer pumps.
By Christian Martin, CIRCOR | Allweiler

M
any production processes
depend on pumps for the
movement of heat-transfer
oils. When selecting a pump, operator
safety and system stability are top con-
siderations, followed by maximum uptime
and low operating costs.
Demanding requirements in
heat-transfer applications
Heat-transfer pumps must operate safely
and reliably to ensure a high level of qual-
ity in production processes. Such pumps
are frequently subject to high loads, and
their failure can have serious conse-
quences, especially if hot oil can escape.
Therefore, operators of heat-transfer sys-
tems are sensitive to leaks. While hot
water normally escapes through the seal
in the form of steam — and usually does
not cause major damage — any escaping
heat-transfer oil rapidly disperses across
a wide area and has a high potential for
serious damage. Any leaks from thermal
oil pumps represent a precarious situation
that requires a rapid, effective response.
And elevated liquid temperature makes
this a challenging task. The solution is
to monitor the rate of leakage to detect
the early stages of seal wear. That way,
pump operators immediately know when
a leak starts.
Pumps used in heat-transfer systems
are subject to high loads induced by ele-
vated temperatures and large tempera-
ture differentials. What’s more, chemical
decomposition reactions often occur in the
pumped liquid whenever the heat carrier
is under high thermal loads. In particular,
the chain-like hydrocarbons decompose
over time into “low boilers” and “high
boilers.” When the proportion of low boil-
ers becomes too high, there is a risk of
pump cavitation. High boilers, on the other
hand, accelerate pump wear and occur in
numerous forms, from a bituminous-like
consistency to highly carbonized products.
Both represent a threat to the bearing and
shaft seal of the pump. The use of syn-
thetic heat-transfer oil reduces the appear-
ance of low and high boilers, but the low
viscosity and lubricity of these materials
have other drawbacks. The tribological
loads working on the sliding components
of mechanical seals are extremely high.
Application example
German-based Odenwald Faserplattenwerk
GmbH (OWA), a manufacturer of acoustic
panels, uses heat-transfer pumps to move
mineral oil at temperatures of approxi-
mately 270°C.

Figure 1. The
Allweiler IN-1000
system from
CIRCOR can be
added to Allweiler
ALLHEAT and NTT
pumps, as well
as compatible
pumps from other
manufacturers if
they are equipped
with standardized
sensors (analog
and digital).
All images
courtesy of
Allweiler |
CIRCOR

26 | April 2019 Flow Control

 The most important elements of any dryer
are the heating register and the heating coils. panel or sent wirelessly to mobile
They impinge heat onto the mineral fiber
panels in a highly uniform manner. Doing
so requires pumps that move the heat car-
rier (petroleum-based or synthetic thermal
oil) to the dryer both uniformly and reliably.
Maintaining the temperatures required of
the process is essential for achieving high
product quality as well as ensuring reliable,
continuous functionality.
As part of OWA’s in-house engineering,
the pumps are in continuous operation
in the heat-transfer systems.
“We often think of the provision of heat
to our production lines as a self-evident fact,” When the appearance of such irregu-
said Jan Herrschaft with the technology
and process engineering department at
OWA. “Our employees in the production
area are focused each
day on maintaining the The system monitors
premium quality of our
the functionality
ceiling panels. The spe-
cial challenge they face of the mechanical
is to have a system that seal, the temperature
is extremely reliable and
allows for preventive of the bearing and
maintenance and a suffi- oscillations in
cient level of digitization.”
In the past, OWA
the pump.
relied on leak detectors
in the collection pans of
the thermal oil pumps. Unfortunately, this
method detected leaks only when they
were already advanced. Preventive mainte-
nance options were also limited. In 2017,
OWA deployed their first Allweiler IN-1000
condition monitoring system from CIRCOR
and added additional systems near the
end of 2018.
The condition monitoring system moni-
tors the functionality of the mechanical
seal, the temperature of the bearing and
oscillations in the pump. If one of the
monitored parameters exceeds the pri-
mary or secondary thresholds, the sys-
tem reacts with the appropriate warning
or alarm messages. The status of each
of the pumps can be read directly from
the display on the master unit, giving
maintenance personnel the opportunity
to respond quickly to disturbances. The
signal can also be optionally transmitted
www.flowcontrolnetwork.com
across an Ethernet to a control
devices. A green light indicates
normal operation. In most cases, a
yellow light draws attention to the need
for pump maintenance. Once the light
switches to red, immediate intervention
is usually required. In some cases, pro-
duction must be stopped.
If significant leaks or high bearing tem-
peratures are detected, the system indi-
cates that the seal is worn or that the
bearing must be replaced. Large oscil-
lations indicate that the pump is out of
alignment or the coupling is damaged.
lar operating conditions is monitored
comprehensively, the operator has the
opportunity to plan for replacement or
repair in a timely man-
ner on scheduled main-
tenance days, thereby
avoiding unanticipated
production downtime.
Early detection of dis-
turbances and wear
saves money by mini-
mizing service and
repair costs.
“For us, disturbance-
free operation is the
most important aspect
and the greatest advantage of monitoring
our systems with IN-1000,” said Herrschaft.
“In addition, we can detect upcoming wear
early and plan for countermeasures.”
The condition monitoring system is also
modularly constructed, which makes it
possible to adapt the module to the sys-
tem being monitored. The master/satellite
combination of the system handles a variety
of monitoring requirements, from straight-
forward monitoring of a single condition
to complex situations with multiple pumps.
The master module is equipped with a web
server that enables remote access to the
master module through a web browser or
the application-specific interface of an exist-
ing process monitoring system via Ethernet
connection. At OWA, the system is integrated
into a larger control system so pump con-
ditions can be retrieved directly, providing
implementation into existing IT structures.
Figure 2. Warnings and alarms for disturbances
and irregular operating conditions can be
retrieved wirelessly on mobile devices.
Cost savings with
continuous monitoring
Condition monitoring systems allow
users to optimize their pumps from
the time of installation. Therefore, an
investment can quickly pay for itself.
For example, when existing installations
were monitored with IN-1000, it was
discovered that up to 75 percent of the
pumps were not properly aligned, which
would have resulted in high oscillations
and ultimately bearing damage and pre-
mature failure. These cases can avoid
costly damages.
Also, integrated data recording enables
precise, daily determination of pump per-
formance, giving users additional ways
to optimize their pumps, such as speed
control or hydraulic optimization.
There are also long-term advantages
of continuous monitoring. Since condi-
tion monitoring systems detect critical
levels of seal wear, the need for preven-
tive maintenance is reduced. This allows
operators to exploit the long service
life of high-quality pumps. As a result,
typical maintenance costs for pumps
in heat-transfer systems are reduced,
while providing operators the peace
of mind in knowing that everything is
under control. FC
Christian Martin is senior director
for product management, CIRCOR |
Allweiler. For more information, visit
www.circorpt.com.
April 2019 | 27
Trade Shows & Events
OTC showcases new technology
and networking opportunities
for the oil and gas industry
T
he 50th annual Of fshore
Technology Conference (OTC)
will be held May 6–9 at NRG Park
(formerly Reliant Park) in Houston. OTC
gives energy professionals an opportunity
to meet and exchange ideas to advance
scientific and technical knowledge for
offshore resources and environmental
matters. In its half century of existence,
OTC has expanded to include the Arctic
Technology Conference, OTC Brasil and
OTC Asia.
The event is sponsored by 13 industry
organizations and societies that work
cooperatively to develop the technical
program. The conference will include
more than 500,000 square feet of exhibit
space as well as more than 350 peer-
selected technical presentations covering
topics from the wellbore to topsides.
More than 60,000 professionals from
more than 100 countries are set to
attend. Typical attendants include engi-
neers, technicians, executives, operators,
scientists and managers in the offshore
energy sector. OTC ranks among the larg-
est 100 trade shows held annually in the
U.S. and is among the 10 largest meet-
ings in terms of attendance.
Sponsoring organizations use revenue
to provide other important programs for
its members, such as training and tech-
nical journals.
Special events at OTC include:
• The Golden Anniversary Opening
Session: The Next 50 Years of Offshore
Developments, where industry execu-
tives will explore how companies are
28 | April 2019
preparing for digitalization, automa-
tion and machine learning.
• The Around the World Series, which
will explore opportunities and tech-
nologies in countries such as the
United Kingdom, Mexico, Saudi
Arabia, Norway and Ghana.
Courtesy of OTC
• The OTC University R&D Showcase,
which provides universities the
opportunity to share with attendees
their current and planned research
and development (R&D) projects that
are relevant to offshore technology.
• The Rice Alliance Start Up Roundup,
which will showcase emerging
energy companies available for
investment.
At OTC, officials will announce the
winners of the Spotlight on New
Logo courtesy of OTC; top photo: FC Staff
EXHIBITION SCHEDULE
Mon., May 6, 9 a.m.–5:30 p.m.
Tues., May 7, 9 a.m.–5:30 p.m.
Wed., May 8, 9 a.m.–5:30 p.m.
Thurs., May 9, 9 a.m.–2 p.m.
otcnet.org
Technology awards. Last year’s 15
winners included Baker Hughes, pro-
ducer of TerrAdapt adaptive drill bit, and
Halliburton, producer of GeoBalance
Automated Managed Pressure Drilling
(MPD) System.
Before the conference, OTC organizers
will recognize the recipients of the 2019
Distinguished Achievement Award at
the Golden Anniversary Gala at the
Downtown Houston Marriott Marquis.
Carlos Mastrangelo will be awarded the
Distinguished Achievement Award for
Individuals for his pioneering efforts in
the worldwide design and adoption of
cost-efficient floating production, stor-
age and offloading units (FPSOs).
The ExxonMobil-operated Hebron
Offshore Project will be presented with
the OTC Distinguished Achievement
Award for Companies, Organizations and
Institutions in recognition of its techno-
logical advancements while achieving
world-class safety performance.
At the gala, OTC organizers will present
the Hoover Medal in coordination with
the American Society of Mechanical
Engineers. David Baldwin, co-president of
SCF Partners, will receive the distinction,
which recognizes extra-career services by
engineers to humanity.
The gala also serves as a fundraiser,
which has raised more than $1.7 mil-
lion to charitable causes. This year, the
beneficiary is Spindletop Charities. The
group provides aid programs support-
ing at-risk youth, mostly in the greater
Houston area. FC
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Featured Products
Send products for consideration in this section
to mrogers@endeavorbusinessmedia.com.
Mass flow controller
Brooks Instrument’s GP200 Series
pressure-based mass flow controller
(P-MFC) for semiconductor applications
enables precise, repeatable control
for gas delivery applications and is
fully pressure insensitive to dynamic
inlet and outlet pressure conditions.
Process gas accuracy is +/-1 percent,
and repeatability is +/-0.15 percent of setpoint. It
was developed based on a combination of absolute
and differential pressure transducers, where a single
differential pressure sensor is used instead of two
absolute pressure sensors to compute pressure drop.
Fusion dampener
Griffco Valve Inc.’s Fusion Dampeners
simplify a chemical-feed system installation
by combining two devices into one
accessory, which reduces the number
of joints, hence fewer leak path
opportunities, and provides for a
nearly pulseless chemical-feed
system. They are available in NPT
connection sizes of ¼ inch, 3/8
inch and ½ inch and two pulsation
dampener volumetric sizes of 6 cubic
inch and 10 cubic inch. They have a maximum
operating pressure of 150 psi (10 bar) at 70°F.
Process pump
ITT Goulds Pumps’ ICO
i-FRAME Pump is an ISO
process pump with i-ALERT
2 intelligent monitoring. The
pump is suited for chemical
slurries, waste liquids, food
and beverage applications and fibrous
materials. The pump is compliant with ISO
2858 and ISO 5199. Available in 34 sizes, it features a
Cyclone Seal Chamber, i-FRAME optimized bearing frame
and robust fabricated steel base plate. It can handle
flows up to 450 m3/hr, temperatures from -40˚C to
280˚C and pressures up to 25 bar.
30 | April 2019
OGI camera
FLIR Systems’ GF620 is a high-
definition, handheld optical gas
imaging (OGI) camera. Designed
for the oil and gas industry, the
camera detects and visualizes
invisible leaks of hydrocarbons,
such as methane, and common
volatile organic compounds. It is calibrated to measure
temperature, allowing the user to assess thermal
contrast between the gas and the background scene
and adjust it to improve visibility. It has a high sensitivity
mode, which accentuates plume movement to improve
detectability in low-contrast scenes.
Subsea safety valve
Interventek’s subsea safety valve, the
Revolution PowerPlus, is powered by a
gas accumulator within the valve, close
to the cutting and sealing mechanism.
It increases the power and speed of
the valve’s functionality and provides a
failsafe mode. It has a compact safety
barrier within the BOP (and below the
primary shear rams) during subsea well
completion or intervention operations.
It can cut any intervention media and seal the wellbore,
containing pressure and allowing the intervention
vessel to disconnect.
RB-DAT
Logan Industries’ Reduced
Bore Direct Acting Tensioner
(RB-DAT) enables the use
of the DAT in shallow water,
following a project that
required making an existing
deepwater DAT suitable
for shallow waters using the existing rod and barrel,
external footprint and interface points, while maintaining
the same pressure rating and tuning the operating
characteristics from deepwater to shallow water. This
can improve the operational performance of the DAT in
shallow waters with lighter loads.
Flow Control
 Connect
SOLUTIONS FOR FLUID MOVEMENT, MEASUREMENT & CONTAINMENT

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 online
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32 | April 2019
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