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Installation Guidelines for Flow Meters

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Tim Dugan P.E., Compression Engineering CorporationFeatured Speaker

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Tim Dugan P.E., Compression Engineering CorporationFeatured Speaker




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Handouts

Engineering Services 2017

▪ Energy analysis services:

For industrial compressed air, pneumatic conveying, process

pumping, industrial process cooling and other similar electric

motor-driven rotating machinery systems:

o Walk-through and development of potential opportunities and

solutions

o Energy efficiency measure selection

o Data-logging

o Data-reduction

o Analysis and simulation

o Project budgeting

o Report writing

o Peer review

o Commissioning

o Inspection

o Re-tuning/re-commissioning

o Energy management

▪ Project technical services:

o Control system specification

o P&ID development

o Equipment layout and piping design

o Ventilation design

o Submittal review

o Commissioning

▪ Miscellaneous services:

o Performance testing

o Tuning and re-tuning

o Leak assessments

o Remote monitoring of key performance indicators

o Project management

o System start-up assistance and trouble-shooting

o Standards and procedures development

o Training


../../2017.03 When to Install a VSD Air Compressor/Handouts/Compression Engineering Corporation Services_2017.doc

../Handouts/Your Audit Guide.pdf

../Handouts/CAT-VP-V-US 1601 LR.pdf

../Handouts/CAT-VP-SMPR-US-1602 LR.pdf

All rights are reserved. The contents of this publication may not be reproduced in whole or in part without consent of Smith Onandia Communications LLC. Smith

Onandia Communications LLC does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained herein, regardless of whether such errors result from

negligence, accident, or any other cause whatsoever.

All materials presented are educational. Each system is unique and must be evaluated on its own merits.



Tim Dugan P.E.,Compression Engineering Corporation

• President and Principal Engineer of Compression Engineering Corporation

•Over 25 years of experience in the compressed air industry

About the Speaker

Sponsored by


Installation Guidelines

for Flow Meters

Tim DuganCompression Engineering Corp.

For Compressed Air Best Practices® Magazine

5-25-17

Presentation is property Compressed Air Best Practices® Magazine

Do not copy or distribute without permission

Outline

• Compressed Air Flow Meter Types

• Metering Systems

• Piping Issues

• Installation Methods

Common Comp. Air

Flow Meter Types

• Thermal Mass:

• Gas mass flow rate calculated from temperature

difference and heating input (mA).

• Low cost, low DP, excellent turn-down, can hot

tap. Available bi-directional.

• For dry, clean air.

Common Comp. Air

Flow Meter Types

• Differential Pressure (averaging pitot tube):

• Gas mass flow rate calculated from DP & density.

• Higher cost, low DP, less turn-down, Can hot tap.

Avail bi-directional.

• For clean or dirty, wet or dry air

Dynamic

pressure port

Positive side

Dynamic pressure port

Negative side

Temperature

FLOW

Common Comp. Air

Flow Meter Types

• Vortex-shedding:

• Gas velocity calculated from frequency of vortices after

a “shedder bar”.

• Low cost, but not mass flow. Need to P&T

compensate. Not bi-directional. Can hot tap. Hard to

troubleshoot.

• For clean or dirty, wet or dry air.

Best Applications for

Comp Air Flow Meter

• Compressor Discharge: DP or Vortex

• Old Un-dried Air Systems (“Mill Air”): DP or

Vortex

• After Dryer: Thermal mass

Metering Systems

• Energy Management, Long-term:

• Long-term Key Performance Indicators:

• “Dead load”, air usage at no production

• “Live load”, air usage related to production

• “Specific air consumption”, flow/production

rate

Metering Systems

• Energy Auditing, Short-term:

• Determine leak load in one area

• Determine air consumption of one usage

Piping Issues:

Network

• Piping Network, “Ladder-type”:

• “Zone metering” recommended, bi-directional

Piping Issues:

Network

• Piping Network, “Looped”:

• “Double tap” metering recommended, bi-

directional

Piping Issues:

Network

• Piping Network, “Linear”:

• “Double tap” metering recommended, single-

directional

Piping Issues:

Condition

• Don’t put a flow meter in a rusty pipe:

Piping Issues:

Condition

• Consider a new pipe run

• Double elbows, diameter changes etc:

• Every upstream element creates some form

of distortion

Piping Issues:

Straight Runs

• Longer is better, double 90’s bad:

Installation Methods:

Insertion

• Wet air: angle is

mandatory to keep

water dripping off

• Dry air: Angle is

recommended to

keep sensor clean

after any dryer

malfunction event

• Stay in Horizontal

Line for DP Flow

Meters – Watch

Min Velocity

30 to 45

degrees


Hot Tap

• Assemble saddle

clamp fitting or

weld on coupling –

1” recommended.

• Screw in threaded

nipple and full

open ball valve


Hot Tap

• Insert hot tap drill

into valve

• Open valve

• Advance drill to top

of pipe surface

• Drill hole

• Back out drill

• Close Valve

• Remove hot tap

drill

Drill bit Threaded

Coupling

(female)

Goes into

valve

Advance

collar

Drill

driver


Hot Tap

• Insert flow meter

• Secure restraint

cable

• Hand tighten fitting


Hot Tap

• Slightly loosen

fitting

• Open valve

• Push meter to

bottom of pipe

• Back meter out

½ of pipe

diameter

• Straighten meter

• Adjust cable &

tighten fitting


In Line

• In-line Can be Installed Without Pre-post

Conditioning

• Better Accuracy if Installed with OEM In & Out

Pipe

Conclusions and

Recommendations

• Use DP flow meters for compressor discharge

• Use thermal mass flow meters for dry air

• Develop permanent metering plan based on

systems approach. Align metering with

maintenance and accounting organization.

• Use best metering strategy that piping allows.

• Avoid permanent metering every little thing.

Budget gets blown with incomplete metering.

• Consider hot tapping and temporary logging as a

continuous improvement tool.

Thank you

Tim DuganCompression Engineering Corp.

503-520-0700

[email protected]


Pascal van Putten, VPInstruments

•CEO of VPInstruments

About the Speaker


Permanent Monitoring of Compressed Air Systems

Your key to maximum energy savings

Compressed Air Best Practices Webinar

May 25th, 2017Pascal van PuttenCEO VPInstruments

www.vpinstruments.com 1©2017 Van Putten Instruments BV. All rights reserved.

Contents

• Introduction

• Why permanent monitoring?

• What is a monitoring system?

• How to monitor?• Common challenges

• How to start

• Implementation

• Future trends

• Conclusions


Solution• Permanent monitoring system• Flow, kW, pressure sensors in 6 compressor

rooms• Aggressive leakage management procedures

Measures• Change to blower air instead compressed air• Use engineered nozzles for cooling• Shut off old sections• Repair and replace old piping

Savings• Total > $ 300,000 per year; ROI: ½ year

Example project: Steel

www.vpinstruments.com 3

Why permanent monitoring?

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

Ene

rgy

con

sum

pti

on

No audit Periodical audit Permanent monitoring


Why permanent monitoring?

• Get to know your factory baseline and fingerprint• Keep a permanent eye on your system: maintain the

savings• Sizing of equipment

(compressors, pipework, downstream consumers)• Monitor and optimize the control system • Maintenance management• Leakage management• Allocate costs


• Flow, Pressure, Temperature, Dew point, kW meters

• I/O modules

• Web-based software

• Alarm functions

• Report functions

What is an energy monitoring system?


TCP/4..20

Eth

ern

et

TCP/485

IO ModuleTCP/485

RS485 sensors

Modbus to Ethernet Converter

SQL

Any Modbus/TCP

sensor

RS485

Modbus to Ethernet Converter

RS485 sensors

RS485 sensors

Flow, Pressure, Temperature sensor Ethernet + WiFi

What is an energy monitoring system?


How to monitor your factory


How to monitor your factory: challenges

People:

- It’s all about habits and behavioral change!

-Lack of interest

-Lack of engagement

-Other priorities

-Lack of experience



Technical

- Old compressed air system (air quality)

- Installation challenges (pipe runs)

- Electrical/ signals: No data infrastructure

- Many tools available, make the right choice


Financial

- Return on investment is unclear

- Maintenance budget energy savings

- Conflicting incentives

-Buyer: Low CAPEX

-Energy Manager: Low energy costs

-Maintenance Manager: Low maintenance costs

Best Practice: “Holistic approach”


How to start: Decide on main KPI’s

Air flow at main header

Efficiency

Leakage flow

Leakage rate

Total amount of compressed air

Cost per X

Compressor power

consumptionAverage flow

Production output

(# products)


How to start?

1. Perform an initial auditIdentify current state

- Compressors’ kW - Compressed air consumption, pressure and

temperature (dry side, main header)- Pressure downstream- Suspicious areas / consumers- Leave the audit equipment in place!

2. Analyze audit resultsHow much can you save:

- What are the top 3 issues?- What is the savings potential?- What will be the ROI?- How to maintain savings?

How to start?

How to start?

3. Install permanent monitoring systemMaximize and maintain your energy savings

- Leave audit equipment (sensors) in place- Install the monitoring platform- Configure alarms, KPI’s and make them available- Expand to other areas: based on facts and generated ROI


Future trends

• Factories become smarter• Permanent monitoring will be standard practice• Big Data and advanced analysis: changing roles• Sensors become smarter• Cloud-based solutions

Cloud

IOT

SmartLogistics

Industry 4.0Big Data

Socialweb


Tips & Conclusions

Permanent monitoring:

• Get to know your factory baseline and fingerprint

• Keep a permanent eye on your system: maintain the savings

• Monitor and optimize the control system

• Leakage management & maintenance

• Allocate costs

Don’t forget:

• It is all about people and behavioral change

• Set the right KPI’s and management policy

• Take it step by step


VPInstruments

Menno Verbeek Sales Manager America’sUSA : 312 239 3052Int : +31 6 43769321 [email protected]

Chuck MaysBusiness Development ManagerVPInstruments North AmericaRaleigh, NCCell: 919 744 [email protected]

www.vpinstruments.com

www.facebook.com/vpinstruments/

www.linkedin.com/company/vpinstruments

Thank you!

Click here to read more on energy monitoring

©2017 Van Putten Instruments BV. All rights reserved.

mailto:[email protected]


https://www.linkedin.com/company/vpinstruments

https://www.facebook.com/vpinstruments/

http://vpinstruments.com/vpvisiondemo/


Ruby Ochoa, Trace Analytics

•Co-Owner and President of Trace Analytics

About the Speaker


The AirCheck Laboratory

Calibration & Compressed Air TestingRuby Ochoa | President & Co-Owner | 1.800.247.1024 ext. 211 | [email protected]

Services & expertise

Manufacturing

Compressed

Air Testing

Calibration

ServicesComing soon...

Breathing Air

Compressed

Air Testing

Microorganism

Compressed

Air Testing

Calibration

Services

Expiration Date Tracking

Notifications & Reminders

Recalibration

Fast Turnaround

Compressed Air

QualityFood Manufacturing & Regulations

GFSI

FDA

FSMASQFI

BRC

BCAS

FSSC

2200

Primus

GFSISPEANSI

ISA

INPO

CABP

What Contaminants Should I Test For?

What Contaminants Are You Filtering For?

CONTAMINANTS

PARTICLES WATER

OILMICRO-

ORGANISMS

Compressed Air

What Purity Standard Should We Meet?

One Size Does Not Fit All

HAZARD

ANALYSIS

CABP

Magazine

DIRECT

CONTACT

[2:2:1]

INDIRECT

CONTACT

[2:4:2]

COMPRESSED AIR

8573

ISO 8573-1:2010 [ P : W : O ]

PHARMACEUTICAL

Risk Assessment - Maintenance

Annual – Quarterly Testing

Representative Sampling Points

Particles: cleanroom specs

Water: -40°F dew point

Oil: as close to zero as possible

NUCLEAR/POWER

Quarterly Testing

Particles: none > 40 microns

Water: Pressure dew point at the dryer outlet shall be

at least 18°F (10°C) below the minimum temperature

to which any part of the instrument air system is

exposed. It shall not exceed 39°F (4°C) at line

pressure.

Oil: Lubricant content should be as close to zero as

possible, and under no circumstance exceed 1 PPM

How Do You Get Started?

Contact Us

NEED A HELPFUL GUIDE . . .

www.airchecklab.com

Ruby Ochoa | President & Co-Owner | [email protected] | 1.800.247.1024 ext. 211

https://docsend.com/view/fdjs452

https://spark.adobe.com/page/PGVN9LIFxszbu/

http://www.airchecklab.com/


Contact

Ruby Ochoa

President & Co-Owner

[email protected]

www.airchecklab.com

1.800.247.1024 ext. 211

The AirCheck Laboratory

www.airchecklab.com

Q&A


Please submit any questions through the Question Window on your GoToWebinar interface, directing them to Compressed Air Best Practices. Our panelists will do their best to address your questions, and will follow up with you on anything that goes unanswered during this session.

Thank you for attending!


Sponsored by



Thank you for attending!

The recording and slides of this webinar will be made available to attendees via email later today.

PDH Certificates will be e-mailed to Attendees within two days.


Sponsored by

http://www.blowervacuumpractices.com/magazine/subscription


Thursday, June 29, 2017 – 2:00 PM ESTRegister for free at:

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Tim Dugan P.E., Compression Engineering Corporation

Keynote Speaker

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