Key points
Introduction
By Mark Iverson, General Manager, AW Lake Company
Digitalisation and the Internet of Things are transforming flowmeters. While many manual flow gauges still operate in the field, flow meters enable real-time monitoring and control of operating status from the convenience of a control room or smart device.
The real-time visibility into operations is very valuable and cost-effective, especially for remote troubleshooting. With manual gauges, technicians must visit a site to diagnose a faulty meter, order the part and, then, return to repair it.
A flow meter can send data on various operating parameters to the cloud for access by different personnel. When identifying a problem, technicians can make quick decisions, immediately ordering the right part without inspecting the flow meter at the location. The result is faster repairs, reduced downtime, and lower maintenance costs.
Control systems receiving feedback from flow meters can make intelligent decisions that something needs attention and create alerts that prompt a call to maintenance. Factory control and automation are similar to the evolution of data in cars. Older models of automobiles feature control panels with gauges that provide readings of gas, oil pressure, etc.
While the driver knows the car status, he must determine how to use that information. Modern cars with sensors alert drivers about low fuel levels as well as how many miles are left before the tank is empty. Cars have slowly evolved into smarter machines by going digital and factories are following this same evolution.
While the move to modern flow meters opens the door to gaining real-time monitoring and control capabilities, don’t throw away those working meters. The addition of an Ethernet converter to old models enables remote access to data across the globe.
Highly skilled experts, either internally at the company or the manufacturer, can troubleshoot or configure a device without manually inspecting the meter and from the convenience of the control room or even remotely with an Internet connection.
Industry 4.0 is also optimising flow meter manufacturing with more seamless data movement through the process – from design through to final production.
For example, custom calibration of flowmeters, without expensive manual processes, can be achieved by entering custom calibration points in the ERP system, where data seamlessly flows to the calibration stands for a more controlled, repeatable and optimised process.
This process enables the manufacture of custom products at the same cost as standard products. By connecting different operations (quality, production, maintenance), Industry 4.0 supports a smoother, more automated process to create a smarter factory.
The continued movement with digitalisation and the Internet of Things will revolutionise the way flow meters are designed, manufactured and operated in the years to come.
Here we have a few of the latest Flowmeters to come into the market, to look out for during 2018:
EE741 in-line flow meter
The modular EE741 from E+E Elektronik can be employed for pipe diameters DN15 to DN50 and is ideal for measuring and monitoring the consumption of compressed air and technical gases up to 16 bar (232 psi).
The modular device consists of the transmitter unit with flow sensor and a stainless steel or aluminium gauge-mounting block. Various mounting blocks allow the use of the EE741 for DN15 (1/2”), DN20 (3/4”), DN25 (1”) as well as DN32 (1 1/4”), DN40 (1 1/2”), DN50 (2”) pipes.
Features include:
- Easy installation and removal
- Highly accurate thermal measuring principle
- Comfortable operation via display
- Several output options
Alicat – in the making
One of the strong Global Trends in gas flow-metering is the ambition to have just one instrument to meet all applications. In reality, this will be hard to achieve as the concept of “all applications” is so far ranging with so many considerations to take into account.
Nevertheless, during 2018 Alicat Scientific expect to be taking a very large step towards this “Nirvana of Flowmeters” based upon combining all of the following technical considerations together in one instrument. The final specifications are still being defined, however, testing has shown that the following specifications are likely, or in some cases, even better.
High Rangeability; Alicat have achieved a turn-down ratio of 2000:1 thereby coming ever closer to the concept of one size fits all. Closely allied to this is the elimination of any measurement uncertainty based upon an element of full scale.
The accuracy statement will therefore be 0.3% of reading across the whole 2000:1 range – essential towards the bottom end of the measurement scale.
Multigas capability, with up to 130 gases stored onboard, with no requirement for conversion factors, the accuracy statement above remains true regardless of the gas type, or indeed of a mixture with up to five constituents.
Multi-parameter measurement, is essential for the selection of just one instrument with an Alicat being capable of measuring volumetric flow, mass flow, temperature, barometric pressure and line pressure.
Most flow applications are for single direction i.e. from a higher pressure to a lower pressure. Some applications, however, require flow in two directions so Alicat have developed their sensor to be inherently bi-directional.
Greater precision within both the process and scientific industries requires that measurement, indication and electronic signals should be as close to real time as is possible. Alicat flowmeters are therefore designed to have a Fast Speed of Response; accurate flow measurements can be obtained within 4 milliseconds.
Linked to both speed and accuracy is the concept of being Instantly on, no warm up, to ensure that all apparatus works to specification immediately upon demand. Lastly, there are three requirements that are linked to flowmeters being unaffected by their surroundings.
Ultra-low Pressure Drop, ensures that the pressure regime within the instrument does not adversely affect the volumetric flow measurement. Conversely, in fact, it also ensures that the instrument does not influence the process within which it is placed.
Attitude Insensitivity, ensures that the instrument can be placed in any attitude without affecting the reading, this is especially important with “balloon gases” that can, with other technologies, suffer from the chimney effect caused by a heating/cooling re-cycle that can result in a zero offset.
Insensitivity to humidity, within the process stream can be important as other measurement technologies often suffer from inaccuracy or functional failure with the presence of moisture.
As has been mentioned above, all of these features will be combined within one instrument; certainly a flowmeter to look out for in 2018.
Endress and Hauser’s Picomag
Picomag is a new smart ‘plug and play’ electromagnetic flow meter that measures and monitors flow and temperature of conductive liquids.
Picomag is ideal for water applications including, cooling, warm and drinking water.
Its compact size makes it ideal for use on process skids where space is limited or in difficult to reach locations. Picomag can be installed into any pipe up to 2”. Picomag offers easy commissioning with Bluetooth using its SmartBlue App, as well as seamless integration in to fieldbus and other existing infrastructures with its IO link technology.
The SmartBlue App allows you to check and adjust parameters in real time at the touch of a button. Outputs also in 4-20mA, pulse, switch and 2-10V.
The multivariable flow and temperature monitoring make it also ideal for production processes in the food & beverage industry.
The stainless steel Picomag flowmeter has high shock and vibration resistance, IP65/67 protection and a PEEK measuring tube. It fulfills EMC requirements according to IEC/EN 61326. It also conforms to the requirements of the EU and ACMA directives, and has a cULus listing.
FLOWave by Bürkert
FLOWaveBürkert’s FLOWave has been developed so that none of the components are in direct contact with the fluid, which causes no restriction to flow. Furthermore, the internal surface of the tube can be manufactured to the same surface finish as the rest of the pipeline, meaning that in terms of hygiene, cleaning and flow conditions, there is no difference to any other piece of straight pipe within the process.
The FLOWave flow measurement device uses Surface Acoustic Wave (SAW) technology that is based on the wave propagation forms similar to seismic waves, which start from an initial point of excitation and spread along the surface of a solid material.
This innovative flow measurement system currently provides very accurate flow and temperature data and the technology will, in the future, allow density information to be used to determine the mass flow rate. Xylem’s Flygt EMF801 MagFlux Flowmeter and MagFlux Quad
Xylem’s MagFlux Quad and WRAS and MCERTS approved Flygt EMF801 MagFlux Flowmeter provides an accurate solution for flow measurement in pipes, offering an accuracy of 0.25%, even when measuring slow flow velocity as low as 0.2m/sec, through to highs of 10m/sec.
The in-built data logger is capable of recording 20,000 entries, giving both an accurate and a consistent reading when measuring flow where space is a premium. Minimum pipe diameter for accurate flow on MagFlux EMF801 3 x Diameter inlet and 2 x Diameter outlet and on the MagFlux Quad only 1 x Diameter inlet and 1 x Diameter outlet and offers a full range of sizes, from DN20 (3/4”) to DN1200 (48”).
IZMAG™ flow meter
The innovative IZMAG™ is a reliable electromagnetic flow meter, functional in design and almost completely made of stainless steel.
The standard version measures bidirectional flows of conductive liquids volumetrically. It owes the reliability of its measured values to continuous internal calibration. The standard model can be expanded using Profibus DP and can be integrated within networks.
The IZMAG™ flow meter can easily be positioned precisely where it is needed: it is available as an all-in-one version, with separated signal transmitter and electronics box, and with an illuminated display that can be rotated through 360°.Installation and commissioning require only minimum effort, saving time and expense.
The IZMAG™ flow meter is a GEA Service product manufactured in Germany – upholding a long and well-proven tradition – and sold at a realistic price.
