gasworld Magazine Issue #07 Supplement August 2015 by gasworld

magazines – website – conferences

www.gasworld.com August 2015 Supplement # 07

Flow control and analysis Trends and technologies in the fundamental world of flow control and gas analysis

→ Going with the flow → Interview: Sierra Instruments

→ Gas analysis in 2015 → WITT: 70 years in gas control

The World’s Most Accurate Thermal Mass Flow Meter.

QuadraTherm 640i/780i ®

NEVER HIGH ACCURACY : FOUR-SENSOR : MASS FLOW METER

before possible.

From Sierra’s beginning over forty years ago, Founder Dr. John G. Olin was driven by his vision to design the world’s most accurate thermal mass flow meter. Two revolutionary technologies, QuadraTherm® and qTherm®, made his vision a reality.

QuadraTherm Sensor This revolutionary new four-sensor design isolates forced convection (the critical variable for measuring gas mass flow rate) by neutralizing unwanted heat-transfer components, like sensor stem conduction, one of the major causes of false flow reading inaccuracies.

qTherm Brain qTherm is a proprietary algorithm set that uses QuadraTherm sensor inputs to solve the First Law of Thermodynamics (Heat Energy In = Heat Energy Out) for thermal dispersion technology. Accuracy never before possible is the remarkable result! Accuracy: +/- 0.5% of Reading Multivariable: Mass flow rate, temperature & pressure Revolutionary QuadraTherm® four-sensor design DrySense™ no-drift sensor with lifetime warranty qTherm™ living, learning “Brain” manages all inputs Dial-A-Pipe™: Change pipe size Dial-A-Gas™: Change gas type qMix™ Gas Mixing Software: Create and upload new gas compositions in the field qTherm Gas Library: 18 gases & mixtures (growing & improving) Digital Communications Solutions: HART, Profibus DP, MODBUS, RTU, Foundation Fieldbus Approvals: ATEX, IECEx, CE, cFMus

sierrainstruments.com North America / 800.866.0200 Europe / +31 72 5071400 Asia-Pacific / +8621 5879 8521/22

SUPPLEMENT: FLOW CONTROL AND GAS ANALYSIS

Contents 4 8

Going with the flow

Flow control in the gases industry

It’s a sensor game

An interview with Sierra Instruments President and CEO Matthew J. Olin.

10 The next quantum leap for gas flow

measurement and control

12 Down and dirty

Tips for accurate metering of digester gases

16 Gas analysis in 2015 22 Process solutions for the products

of tomorrow

An interview with Martin Bender, Managing Director of WITT

low control and measurement is a fundamental in the industrial gases industry, as exemplified by the wealth of flow meter technologies and products in the market. A high return on investment is the goal for most industries, and the choice of flow control can ultimately provide this. And as end-user applications and processes continue to evolve, coupled with ever-tightening environmental compliance, greater emphasis is placed on the gas supply chain and the flow control technologies that assure accuracy and repeatability of product data. Accurate and consistent flow control not only improves processes and analysis, but also reduces contamination, material waste and ultimately affects the bottom line in terms of enhanced efficiencies and cost savings. Here in this supplement we speak exclusively with one of the pioneers behind many of these products, Sierra Instruments, while fellow flow control innovator Bronkhorst discusses the next quantum leap in the field as it takes us on a technical journey through the El-Flow Prestige range of thermal mass flow meters and controllers. Of course, any discussion of the world of flow control and measurement would not be complete without mention of the extended family in this business – gas analysers and related technologies. From page 16 we explore the trends in gas analysis in 2015, complemented by an interview with WITT’s Martin Bender from page 22, celebrating 70 years in gas analysis. Rob Cockerill Managing Editor

Team Managing Editor Rob Cockerill rob.cockerill@gasworld.com Web Editor Stuart Radnedge stuart.radnedge@gasworld.com Production Manager Jon Evans jon.evans@gasworld.com Graphic Designer Mark Mitchell mark.mitchell@gasworld.com Graphic Designer Karen Skinner karen.skinner@gasworld.com Media Sales Manager Ron Leitch ron.leitch@gasworld.com Advertising Manager Kevin Murphy kevin.murphy@gasworld.com Advertising Sales Executive Rob Allwright rob.allwright@gasworld.com Directory Sales Executive John Thomson john.thomson@gasworld.com

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Going with the flow Flow control in the gases industry

high return on investment is the goal for most industries, and the choice of flow control can ultimately provide this. Getting the maximum out of a given process or system could be the difference between profit and loss, safety and danger. When it comes to flow measurement and control, every gas molecule matters â&#x20AC;&#x201C; whether applied in the industrial gases business or beyond. Flow meters and instrumentation are applied across a range of industries, operations and processes around the world. Applications range from energy research and production through to the metallurgy sector and the food and beverage 04 | gasworld supplement | August 2015

industry. A particular example might be the life sciences market, where research and development in the areas of biotechnology, cryobiology and pharmaceuticals places high demands on precision instrumentation. Precise data capture is also essential in the analytical market, with bespoke flow meter devices deployed in gas sampling, gas chromatography (GC) and mass spectrometry (MS), while mass flow instruments have a growing role to play in environmental applications as tighter emissions control drives demand for precise greenhouse gas (GHG) sampling. And the drive for precision only continues. Process and

GOING WITH THE FLOW

plant engineers are continuously challenged by productivity and efficiency objectives, as well as ensuring that operations comply with ever-expanding regulatory demands. As a result, the requirement for accurate and repeatable data, diagnostics and measurement is ever-increasing. While for gas mixing and blending applications this has always been a core requirement, the entire flow control industry is striving for continual improvements in accuracy and performance like never before. It really is a case of going with the flow in 2015. Flow meters Capable of operation under either positive or negative vacuum pressures, a mass flow instrument both measures and controls mass flow directly. In fact, the instrument is not actually influenced by changes in the temperature or pressure of the gas stream – ensuring that a mass flow meter (MFM) or mass flow controller (MFC) can provide accurate measurement of a given substance or sample for a variety of applications. With the flow meter having undergone significant evolution and development over the decades, a range of flow sampling systems exist for varying applications and set-ups. One of the first users of mass flow controllers was gas chromatography, while precision gas flow meters and controllers are often used to control calibration gases in analytical and semiconductor settings. In the food and beverage business, high pressure gas flow meters and controllers manage the process of injecting a gas like nitrogen into a food package to create an inert atmosphere, and flow meter devices are used in almost all manufacturing processes to control precision mixtures of various gases. For the measurement of gases alone, variations in density can afford different challenges or requirements, placing emphasis on the correct choice of flow meter. Whereas mass flow meters are independent of temperature or pressure changes in a gas stream, as described, volumetric gas flow meters are sensitive to these changes, for example. A thermal mass flow meter might also be an option for the user, depending on the application or purpose. Drivers such as the proliferation of natural gas discoveries – as is the case in North America, for example – and the increasing quest for accuracy in product quality in the food processing

“Drivers such as the proliferation of natural gas discoveries and the increasing quest for accuracy in the food processing and chemicals industries are propelling developments in flow meter technologies...” and chemicals industries are propelling developments in flow meter technologies, and thermal flow meters in particular. Leading engineers in the process community are understood to be increasingly recognising thermal dispersion flow meter technology, for example, a mass flow measuring technology, as an effective, low cost and high reliability solution for their gas flow applications. Cryogenic flow meters are another means of measurement and control. These instruments can be fitted to bulk liquid tankers to enable the accurate measurement of the quantity of liquid gas delivered, for example. Some mini-bulk tankers on the market even come with liquid flow meters that have an integrated printer to produce an on-the-spot delivery note and transmit data for later invoicing. Pressure gauges, valves, and regulators The role of other instruments, including pressure gauges, valves and regulators, in the world of flow control should not be overlooked. Part of the process instrumentation family, the pressure gauge is a significant safety device in gas and liquid pressure regulation. Gas pressure regulators are used to reduce the pressure of gas supplied from a high-pressure vessel to a safe and workable level that can be safely used for operating equipment and instruments.

PRINCIPLES OF FLOW METER TECHNOLOGY Accurate and consistent flow control not only improves processes and analysis, but also reduces contamination, material waste and ultimately affects the bottom line in terms of enhanced efficiencies and cost savings. Flow control is important as the critical variable in most processes is mass, not volume. With changes in temperature and pressure capable of changing the density

of a fixed volume of gas, mass flow measurement – which is largely immune to fluctuations in inlet temperature and pressure – is considered more important than volumetric flow measurements. The accuracy of mass flow meters and mass flow controllers themselves is essentially determined by two factors – flow calibration and repeatability. A range of mass flow control principles exist. In

terms of mass flow control, an output signal is continuously compared with a set point signal from a voltage source; any deviations between these two readings are translated into control vave adjustments until identical. In a CEM (Control-Evaporation-Mixing) Vapour Control application, for example, a liquid is drawn from a vessel with an inert gas membrane and

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As part of this function, pressure gauges measure the pressure of a gas or liquid in a process and ensure accurate pressure control over a wide range of parameters and are particularly suitable to users seeking constant gas pressure at the outlet point – even when consumption is fluctuating. Pressure gauges therefore serve not only a crucial safety purpose, but also contribute to cost-efficiency benefits. While largely uniform in their remit – to measure the pressure of a given gas or liquid – a whole range of these devices is available. Various pressure gauges are developed for different applications and specifications; identifying the right pressure gauge for an application depends on a number of factors, including the nature of the fluid or gas, the temperature and working pressure, and the external environment. Similarly, a plethora of valve and regulator technologies exist for the control of pressure and flow. The packaged gases business is a good example. Compressed gas cylinders require the installation of at least one valve, fundamental to keeping ‘slippery’ gases under control. Escaping gas can potentially cause serious health, safety and environmental issues, in addition to obvious financial implications, while gas entering the cylinder or the supply system can cause unwanted contamination – an issue in the specialty gases business in particular, where high purity and ultra high purity (UHP) gases are compromised by contamination. When the intention is to expel gas out of a cylinder, regulators to control pressure and valves to control flow rate are needed. Gas pressure regulators, for example, are used to reduce the pressure of gas supplied from a high-pressure cylinder of gas to a workable level that can be safely used for operating equipment

and instruments. Flow control in the cryogenics industry is another significant example, with valves one of the most critical components in this area. Cryogenic valves normally refer to valves with working temperature below -110°C, widely used in industrial gas, LNG and other low temperature applications and regulating or controlling the flow of cryogenic gases, slurries or liquids at low temperatures. When considering the robust investment programme of industrial gas projects worldwide, coupled with the boom in LNG and the inherent synergies between the two businesses, the demand for cryogenic valves has been seen to increase considerably – providing valve manufacturers with strong business opportunities the world over, and particularly in the buoyant Asia-Pacific region. Marine LNG applications have been especially notable in recent years, with valve manufacturers such as Herose GmbH and Bestobell Marine – for example – announcing various contracts to this effect. Going with the flow… As end-user applications and processes continue to evolve, coupled with ever-tightening environmental compliance, greater emphasis is placed on the gas supply chain and the flow control technologies that assure accuracy and repeatability of product data. From the quest for higher pressures, like the potential rise of 700 bar hydrogen refuelling, to the increasing demand for cryogenic valves for LNG applications and growing requirements for thermal mass flow meters in hydrocarbon operations, industry focus on flow control only intensifies. gw

PRINCIPLES OF FLOW METER TECHNOLOGY CONT. measured by a liquid mass flow meter – controlled to a set point value by a control valve. The mixture is then passes through an evaporator to achieve ‘total evaporation’. Thermal mass flow meters continue to advance and grow in their application. Such devices make use of the heat conductivity of gases or liquids to determine the mass flow. Bronkhorst UK explains that two sub-principles exist for measurement of gases: the by-pass principle, and the inline principle. During the by-pass principle, part of a given gas stream flows through the sensor and is warmed up by heaters, with any difference in the measured temperatures directly proportional

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to mass flow. In the inline principle, two stainless steel probes – a heater probe and a temperature sensor probe – protrude into a straight flow channel, with a constant temperature created between the two. The energy required to maintain this temperature is proportional to the mass flow rate. Based on this concept, mass flow can be measured with low pressure drop. Unlike the traditional by-pass principle of thermal flow meters and controllers, the measurement of constant temperature is less sensitive to humidity and contamination. For liquids, thermal mass flow meters are built around a stainless steel tube without moving parts of obstructions.

The heater/sensor assembly is arranged around the tube and a constant difference in temperature is created – with the energy required to maintain the constant temperature dependent on the mass flow rate. Another option in mass flow control is the Coriolis principle, a fast and accurate means of measurement. A mass flow meter operating on the Coriolis concept comprises a vibrating tube through which a fluid flow causes a change in frequency, phase shift or amplitude. The resulting output signal is strictly proportional to the real mass flow rate, whereas thermal mass flow meters are dependent on the physical properties of a given fluid.

TRI-CON SERIES FOR LOW TEMP

APPLICATIONS

WWW.ZWICK-ARMATUREN.DE

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It’s a sensor game Sierra Instruments continues to challenge the industry status quo and realise the vision of its forefather with innovation in sensors, software, and flow control. An interview with Sierra Instruments President and CEO Matthew J. Olin.

rom Sierra’s beginning over 40 years ago, founder Dr. John G. Olin was driven by the vision of supplying industrial customers with the world’s most accurate mass flow meter. And, he knew it was a ‘sensor’ game. With a background – and Ph.D. – in mechanical engineering and specialised in fluid mechanics and heat transfer, Olin was a driven innovator and founded Sierra Instruments Inc. in 1973 with the purpose of offering industrial grade thermal mass flow meters to solve industry’s need for rugged, reliable flow meters based on the thermal principle. The development of an industrialised metal-sheathed sensor in the early 1980s was Sierra’s first big step, but was only the beginning for Dr. Olin, who saw ‘thermal mass flow’ as his life’s work. Many successful innovations followed, including a major breakthrough in 1999 with the introduction of Sierra’s patented no-drift DrySense™ mass velocity sensor. With this development, Sierra engineers recognised they were on the cusp of realising Dr. Olin’s vision. Now a second-generation business, today Sierra has nearly 200 employees, facilities in five countries, and agents in no less than 53 countries. The company has grown substantially under the leadership of Dr. Olin’s son, Matthew J. Olin. President and CEO since 2003, he imbues the company’s focus on building a great company, not stock price, and creating innovative products that continually change the way people think about industrial companies. Sierra has pioneered with a number of firsts throughout its history, starting in the early 1980s with the first mass flow meter (MFM) and mass flow controller (MFC) with a cleanable sensor – the SideTrak® – and more recently the first digital MFC with multi-gas capability (Dial-A-Gas®) with unique local pilot module display interface – SmartTrak® – and the first four-sensor thermal mass air/ gas flow meter design in the shape of the QuadraTherm 640i/780i. Recent product releases include the SmartTrak® 140 Ultra-Low ΔP for semiconductor applications, the SmartTrak® 100 High Pressure for pilot plants, a cryogenic version of the InnovaMass® 240 multivariable mass vortex flow meter, and the SmartVO™ Control Valves range. With this in mind, we asked Sierra’s CEO about markets and innovation. “Sierra is responding to market/industry demands by continually creating effective and innovative products that meet the needs in those markets,” Olin says. “Specifically over the past few years we have brought to the market the world’s first QuadraTherm® 640i/780i thermal dispersion mass flow meter. The first of its kind with patented four-sensor technology, it offers unparalleled +/-0.5% accuracy plus our latest release, new gas mixing software that allows

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customers in oil and gas and other industries to do in-the-field-gascomposition changes/creation without loss of accuracy.” Olin refers to Sierra’s new qMix gas mixing software which, for the first time, allows oil and gas engineers to field adjust their gas composition on thermal mass flow meters in the field for flare, Vapour Recovery Units (VRU’s), and storage vessels without sending the meter back to the factory for recalibration. The new software package is included with every QuadraTherm 640i/780i thermal mass flow meter on a beta trial basis and is a unique feature of Sierra’s Smart Interface Program (SIP) software, unlike anything available on the market for industrial mass flow meters. The ability to create custom gases or gas mixtures to compensate for gas compositional changes in the field without accuracy loss means oil or gas engineers can easily meet US EPA Directive 40 CFR Part 98 for shale gas upstream production operations since they can use qMix when the gas composition changes in the pipe, or when moving the meter to another location with a different gas composition. This is potentially a game-changing solution in flow control; traditionally, thermal mass flow meters are calibrated using the exact gas mixture they are intended to measure, or a surrogate mixture with very similar properties. With the qMix-enabled QuadraTherm, end-users are able to field adjust and maintain flow meter accuracy if the gas composition changes – avoiding costly recalibration. Sierra is,

IT’S A SENSOR GAME

therefore, hailing the QuadraTherm 640i/780i with qMix as the ‘perfect solution’ for challenging shale gas upstream production applications. With the energy sector under continual – and rapid – evolution today, and of increasing significance to the industrial gas and equipment community, the launch of Sierra’s qMix software exemplifies its founder’s quest to develop flow control solutions for industry’s ever-changing needs. Realising the vision in flow control This mission was, and is, no mean feat. Thermal technology, by its very nature, uses the physics of heat transfer and conservation of energy in an open system to measure mass flow rate. This means that for a thermal mass flow meter to achieve the greatest accuracy, it must first solve the First Law of Thermodynamics (Heat Energy In = Heat Energy Out) for each data point. “As you can imagine, solving the First Law in a flow instrument was no easy task,” Olin explains. “By Dr. Olin’s own accounting, decades of ‘hard-nosed dedication to excellence’ by himself and Sierra’s engineering team, years of testing, and his stack of yellow note pads over five feet high, jammed with his handwritten equations and designs, finally yielded the secret in the form of two revolutionary technologies – the QuadraTherm® and Raptor™ II – now both patented worldwide.” Traditional thermal sensors have two sensors – one temperature sensor and one velocity sensor, each in a separate probe sheath. QuadraTherm (the term ‘Quad’ meaning ‘four’) introduces four sensors – three precision platinum temperature sensors and one patented DrySense mass velocity sensor. “Sensor performance improvements never thought possible are gained with QuadraTherm as forced convection is completely isolated (the critical variable for measuring gas mass flow rate) by calculating and then eliminating unwanted heat-transfer components, like sensor stem conduction, one of the major causes of false flow readings,” Olin adds. The ‘true’ brains behind this is Sierra’s Raptor II operating system (formerly known as qTherm), a revolutionary, living, learning algorithm set made possible by today’s hyper-fast microprocessors and QuadraTherm sensor inputs. Olin explains, “At Sierra, we refer to Raptor II as our ball-of-math. It manages changes in gas flow, gas temperature and gas pressure, as well as outside temperature, via a comprehensive heat-transfer model. The result is a proprietary, fundamentally different gas mass flow rate calculation using all pertinent variables for the most precise, stable and accurate mass flow measurement possible.” High flows, high pressure and ever-higher accuracy Sierra’s products can affect an industrial gas company’s bottom line by helping to improve the quality of their product, reduce utilities costs, reduce operations and maintenance cost, reduce capital and engineering, provide accurate date for any environmental and

AeroMax contouring elimates downdrafts Pressure Sensor Port (optional) QuadraTherm (T2) Temperature Sensor QuadraTherm (T4) Temperature Sensor QuadraTherm (T1) DrySense Velocity Sensor (cutaway view) QuadraTherm (T3) Temperature Sensor Stand-off protects Sensor tips © Sierra Instruments | Four-sensor technology by Sierra.

regulatory requirements, optimise throughput, reduce waste, and improve availability. Indeed, Olin affirms that ever-higher accuracy and turndown, high flows, field calibration and validation, and changing gases and gas composition ‘on the fly’ are hot topics right now in the world of flow control. But flow control at the industrial gas plant is one of a number of applications driving growth for Sierra in 2015. Flow ‘energy’ measurement and management, ultra high purity gases in the semiconductor sector, high pressure pilot plants, and very high flows and changing gas compositions in the oil and gas business are all significant opportunities for the Sierra of both today and tomorrow. The common challenges across all applications are: • Increasing accuracy to improve quality and throughput • Lowering measurement costs – total cost of ownership • Flexibility with changing application conditions in the field. This, Olin says, will create opportunities in flow control for multivariable meters. “Accuracy is dollars, and if one flow meter can perform in many different applications, customers like to buy all the same meter types to reduce cost and maintenance.” It’s a market that Sierra, thanks to the vision of its founder and its ongoing innovation throughout the decades, is ready to serve – and enable. Olin concludes, “Sierra has a bright future focused heavily on the energy, environment and natural resource markets. We believe in thinking ahead and always working with an uncompromising focus on QDPICS™ (Quality, Delivery, People, Innovation, and Customer Service).” “We believe by focusing on our customer needs and continually challenging the status quo in our industry, we will always be able to respond and anticipate customer’s needs.” gw August 2015 | gasworld supplement | 09

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The next quantum leap for gas flow measurement and control

ronkhorst® has successfully supplied gas, liquid and vapour flow/pressure measurement and control instrumentation to numerous industries for over 34 years. This success, entirely based upon close collaboration with their customers, has resulted in countless industry-changing advances in both measurement technology and its implementation within continuous process improvement. The latest generation of its El-Flow Prestige thermal mass flow meters and controllers, however, represents a truly groundbreaking shift in versatility and user-friendliness, the company says. The principal customer benefits are based upon: • Further advances in flow-signal processing • A highly stable flow control regime virtually impervious to process fluctuations • Highly advanced control valve design • An on-board gas conversion model • Significantly reduced power consumption • A user-configurable device with a multitude of additional features and benefits. These benefits were developed in response to the specific needs of industry to constantly improve both the technological and commercial basis upon which economic success is based. The close collaboration mentioned above highlighted very clear

EL-FLOW PRESTIGE – FLOW SIGNAL RESPONSE

requirements to increase yield, profitability, process stability, quality, flexibility, lifetime and MTBF. At the same time, these benefits would be required to decrease waste, energy, re-work, inventory, cost, down-time and complexity. For Bronkhorst, the ElFlow Prestige has answered ‘each and every one of these needs and a few more besides’. A fundamental cornerstone of the Bronkhorst ethos is ‘constant improvement in all that we do’ and this dedication to excellence has, over many years, realised a number of world-class innovations. Within the field of thermal mass flow measurement, Bronkhorst has applied its vast R&D capability to further technological advances based upon the following five core developments. The sensor – Now benefits from the enhancement of the Differential Temperature Balancing technique whereby the two sensor windings are power regulated to the same temperature above the gas stream ambient. Upon flow, the difference in power between these two windings to maintain the same measured temperature is directly proportional to the mass flow. This technique, and the sensor design, provides significantly increased

EL-FLOW PRESTIGE – REAL FLOW RESPONSE

Flow [% of 5 In/min]

100

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0 300

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400

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THE NEXT QUANTUM LEAP FOR GAS FLOW MEASUREMENT AND CONTROL

reproducibility, linearity within the calorimetric flow regime, insensitivity to humidity fluctuation and the eradication of signal fold-over upon flow saturation.

The control valve – Advanced reengineering has resulted in smooth and frictionless control characteristics that have a direct positive impact on stability, longevity of response, and MTBF.

20 15 10 5 0

Nominal flow

30 Flow

DTB sensor steering

Temperature increase by added power

Temperature profile

The Laminar Flow Element – At the very heart of the Bronkhorst El-Flow Prestige is the LFE or ‘shunt’ that determines the proportion of flow between the bypass sensor and the main flow channel. Engineering improvements have been applied to enhance the empirical instrument accuracy as well as further improving flow-pressure drop linearity.

25 Sensor signal

The PC-Board – Whilst being completely re-designed for increased speed and processing power, the PC-Board also includes an on-board EEPROM for data storage and enhanced temperature measurement for sensor signal steering and optimisation, together with the support of multiple fieldbus communications and user selectable in/out options accessible via pin5 of the electrical connector. These improvements have been achieved whilst also significantly decreasing the power consumption of the device.

Temperature decrease by flow

Constant power steering

Temperature decrease by decreased power

Temperature increase by convected heat

T-sensor temperature Flow direction

The electrical housing – The solid sensor capillary metal housing is now more userfriendly than previously, has yet further increased EMF stability, is now UL approved, and is common across all fieldbus options. Further technical advancements include an extremely fast dynamic response, an on-board gas conversion model, 25 selectable gases together with the on-board calculation of mixtures with up to five components, user selectable full-scale flow range-ability within 40% and 120% of the nominal capacity, downturn of 150:1 in digital mode, user configurable control characteristics, various on-board alarm and counter functions, and

upstream winding

downstream winding

an optional integrated shut-off valve. The Bronkhorst El-Flow Prestige Series has been developed to meet the ever more stringent needs of industry for greater process precision, stability and cost control whilst eliminating down-time, waste and re-work. Close working relationships and collaborations have been seen within applications for the compound semiconductor, nanotechnology, glass coating, optical fibre manufacturing, specialty gas, pharmaceutical, chemical, analytical, R&D and university research industries to name but a few. gw August 2015 | gasworld supplement | 11

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Down and dirty Tips for accurate metering of digester gases By Jeff Smith

he primary goal of the the municipal wastewater treatment process is to remove suspended solids, biodegradable organics, pathogenic bacteria, and nutrients from the wastewater before it is allowed to be returned to the environment. Wastewater treatment includes physical, chemical and biological processes, including chemical addition, coagulation, flocculation, sedimentation, filtration, and disinfection in order to decontaminate the water. Sludge, the by-product of the treatment process, is further treated to make it safer for the environment. The sludge is placed in 12 | gasworld supplement | August 2015

heated oxygen free tanks, called digesters, for two to three weeks. Digestion fuels the growth of anaerobic bacteria, which consume organic material in the sludge. The anaerobic digestion process stabilises the thickened sludge by converting much of the material into water, carbon dioxide and methane gas. The resulting biosolids are then dewatered for easier handling and often applied to farms to improve vegetation growth or processed further as compost or fertiliser. During this digestion process, biogases, or digester gases, are created as by-product of the decomposition of organic matter by

TIPS FOR ACCURATE METERING OF DIGESTER GASES

anaerobic bacteria. Digester gas is typically composed of about 60% methane (CH4) and 40% carbon dioxide (CO2). However, these gases pose safety and environmental concerns, emit unpleasant odours, are combustible, and are considered greenhouse gases (GHG). According to the Environmental Protection Agency (EPA), methane can stay in the atmosphere for roughly 12 years; pound for pound, the impact of methane on climate change is over 20 times greater than CO2 over a 100-year period. Although wastewater management facilities account for only 2% of US methane production, a significant amount is released into the atmosphere, and increasing regulations are demanding that the emission of greenhouse gases be properly monitored. Proper handling methane and other digester gases appropriately is challenging because they retain gas properties at normal conditions and temperatures. It has been common practice for facilities to flare digester gas at high temperatures, the goal of leaving few residual effects. Many facilities have come to realise that digester gas is a reliable and abundant fuel substitute for natural gas for some on-premise applications, such as boilers, hot water heaters, reciprocating engines, turbines, and fuel cells. Certain facilities are affiliated with feed-in programmes and sell surplus electricity back to the local utility. While the wastewater facility benefits from the energy and heat it can generate, the facility is reusing its digester gases to lower its GHG emissions and keep within the regulatory requirements – and better contribute to local communities. There are added incentives to reuse digester gas. In California, for example, the California Public Utilities Commission has a programme called the Self-Generation Incentive Programme (SGIP), which provides financial consideration when facilities utilise these waste gases for waste-to-heat power, gas turbines and emerging technologies, such as fuel cells. The recently revised SGIP programme provides payments up to $1.65 per watt generated by these systems. These facilities also realise significant operational savings when they calculate the lower electricity usage that would be needed for power, heating, cooling, and more besides. In addition, the EPA created 40 CFR Part 98 or the Greenhouse Gas Reporting Programme, a rule for the mandatory reporting of greenhouse gases from large emissions sources in the US. This program applies to direct greenhouse gas emitters, fossil fuel suppliers, industrial gas suppliers, and facilities that inject CO2 underground. In general, facilities that emit 25,000 metric tons or more of CO2 equivalent per year must report it. Facilities that fall below the 25,000 metric ton limit are not required to report their emissions to the EPA. With all of these factors in mind, it’s becoming more important than ever for facilities to be able to monitor, measure and properly utilise the gases created in the wastewater treatment process. However, there are several issues that make measurement difficult. Digester gases are typically wet and dirty and flow at low or irregular pressures, and maintaining an accurate reading in fluctuating, dirty environments can be challenging.

“A common solution for digester gas calculations are thermal dispersion type mass flow meters...” Solutions The digester gas environment requires a meter that is rugged and capable of handling the wet, dirty debris in the lines. Despite these tough conditions, the meter must be accurately and reliable. Several types of meters can be used for this application. However, engineers must look at how these technologies perform over the long-term. Thermal dispersion type mass flow meters A common solution for digester gas calculations are thermal dispersion type mass flow meters. These meters are inserted into the pipeline, are easy to install and have no moving parts. When installed correctly, these meters claim to provide flow accuracy of ± 0.75%. The overall benefit of using a thermal dispersion flow meter is that it offers a packaged solution for a mass flow rate. In essence, it provides engineers with the necessary numbers without requiring calculations – therefore delivering a one-stop reading for digester gas measurement. However, there are some downfalls to this solution. As a thermal dispersion meter is electronic and relies on sensors inserted into the pipe, it can be contaminated and become inaccurate due to the constant exposure of the dirty, wet digester gas. If these meters begin to fail, it may be difficult for municipalities to repair them on their own or with little support from the manufacturer. In addition, these meters must be regularly cleaned and calibrated, and it can be argued that the correct method for calibration should be done by a knowledgeable field engineer trained to produce verifiable results. August 2015 | gasworld supplement | 13

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Fill and Vent Plug

0° 90°

270° Flow 180°

Isolation Valves Recommended Drain 3-Valve Manifold

Differential type meters The best option for monitoring digester gas in wastewater facilities is a proven, accurate solution that has been implemented by wastewater treatment facilities around the world for generations. Differential-type meters, such as the Venturi, can be field-calibrated and are traceable and verifiable. Although these meters are subject to blockages due to debris and the viscous digester gas material, they are physically equipped with clean-out ports to make this easy for facility technicians to conduct on a regular basis. For example, the HVT-DG from Primary Flow Signal is designed specifically to deliver reliable service despite very low line pressure and dirty, wet gas environments. Although any typical Venturi meter can monitor digester gas, the HVT-DG features a tap cleanout rod for both the high and low pressure sensing points that allows for the removal of particles from the meter, offering a simple solution to ensure debris does not impact flow measurement. This specialised, insertable Venturi meter is customisable and is available in a standard configuration, as well as special configurations designed for any line size, and for the specific conditions of each application. The HVT-DG maintains an accuracy of ± 0.50% of actual reading or better and can handle temperatures up to 350°F with the appropriate selection of materials. Although measurements require calculations and are not automatically displayed like thermal dispersion type mass flow meters, the HVT-DG delivers accurate 14 | gasworld supplement | August 2015

measurements without the requirements for recalibration. In addition, when paired with secondary metering elements, the read-out will compensate for line conditions, greatly improving overall accuracy. In the end, the HVT-DG provides a long-term, reliable solution that can be independently verified and calibrated. Conclusion Environmental requirements and financial incentives for accurately monitoring and repurposing digester gases are further increasing the demand for effective and reliable digester gas measurement. Facilities can justify the investments in more accurate meters as the business case continues to be proven out. gw

ABOUT THE AUTHOR Jeff Smith is the National Sales Manager at Primary Flow Signal. He has worked in the instrumentation and process controls market for over 30 years. In 1995, Smith founded Alpha Valve & Controls, a manufacturer’s representative firm specialising in flow measurement instrumentation, representing PFS Venturi Flowmeters, as well as magnetic, ultrasonic, open-channel, and Area X Velocity flow meter manufacturers. He joined Primary Flow Signal following the sale of Alpha Valve & Controls in 2007.

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Gas analysis in 2015

arlier this summer, Porvair Filtration Group declared its belief that the global energy challenge will increasingly be met through tried and tested gasification technology. As an international leader in filtration and separation, it is perhaps little wonder the company believes so. But, as the company points out, there are a number of recognised market drivers that are pointing to the increasing use of gasification technologies in the future. Environmental accountability, feedstock availability, diminishing waste storage, and enhanced energy security needs are all key dynamics. While this will undoubtedly be good news to those doing business in the gasification and filtration equipment niche, it could also bring benefits to the market for gas analysis. Back in October 2014, for example, Servomex announced that 16 | gasworld supplement | August 2015

it had been awarded a major contract by Reliance Industries Limited (RIL) to provide oxygen (O2) and carbon monoxide (CO) measurement analyser packages – complete with sample handling systems – for the world’s largest gasification project at RIL’s J3 Refinery in Jamnagar, India. The first package for the project involved the provision of no less than 43 SERVOTOUGH OxyExact 2200 high specification process O2 analysers, while the second package will deliver 40 SERVOTOUGH SpectraExact 2500 photometric gas analysers specifically chosen for its sensitivity in low range CO measurement. And that’s before the wave of growth in gasification technologies has even started to build. Such an order demonstrates the potential ahead in this area, and perhaps exemplifies the gas analysis market in 2015/16 – driven as it is

GAS ANALYSIS IN 2015

“...the most significant technology change in recent years has been the introduction of diode laser-based infrared analysis”

by emerging economies, an evolving energy sector, increasing environmental/emissions pressures, and the ongoing quest for stable, repeatable and accurate analytics. Growth drivers Energy and environment are certainly two growth drivers for the analyser business, and we can highlight two distinct developments in the marketplace in the last year as evidence of this. Firstly, the acquisition of Gasmet Technologies Oy (Gasmet) by Nordic growth capital investor Alder cited Gasmet’s position as a world-leading innovator within the environmental instrumentation sector as a major factor in the deal. The company’s products are employed globally in regulatory monitoring, process control and environmental/safety

applications by some of the world’s major organisations, with Alder keen to both tap into and accelerate the expected growth in these areas. Dag Broman, Partner at Alder, said of the deal, “Climate change and environmental protection represent two of the world’s greatest challenges, so Gasmet is ideally placed to exploit the opportunities that they present...This acquisition is a long-term investment to help drive Gasmet‘s future success in accordance with our strategy to support the development of strong Nordic companies in the environmental technology sector.” Secondly, February 2015 saw AMETEK Process Instruments introduce a third generation hydrogen sulfide/sulfur dioxide (H2S/ SO2) tail gas analyser for the petrochemicals, chemicals, refining and steelmaking sectors, with significant reliability advances for control of the Claus sulfur recovery process. New features of the Model 888 Sulfur Recovery Tail Gas Analyser overcome the three most common external failure modes encountered by sulphur recovery units (SRU), including automatic flow control for proactive response to adverse process conditions such as liquid entrainment during SRU turndown. But there are also wider growth drivers at play in the gas analysis business, many of which can be attributed to technology development itself. Indeed, AMETEK told gasworld last year (2014) that the most significant technology change in recent years has been the introduction of diode laser-based infrared analysers. These analysers use the modulated output of near infrared diode lasers to analyse small gas phase molecules at the parts-permillion (ppm) level. The reliability of accuracy from gas analysers is of paramount importance to all involved in what is a results-driven industry, and this has been at the core of a number of product launches of late. Servomex launched the SERVOTOUGH MiniLaser Oxy in January, the world’s smallest cross-stack Tunable Diode Laser (TDL) gas analyser and the only TDL analyser specifically optimised for oxygen measurement. The MiniLaser can be installed quickly, by just one person, and is optimised for the fast, accurate and responsive measurement of process oxygen in hot or hazardous conditions, exactly where it is needed – particularly suitable for a range of combustion and process control applications. Described as ‘the next big thing in gas analysis’ by Servomex President Chuck Hurley, the introduction came ahead of a number of key product updates in 2015 as analyser technology continues to evolve. The company has updated its DF-700 ultra-trace moisture analyser range with new firmware and an improved August 2015 | gasworld supplement | 17

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user interface, for example, optimised for semiconductor, LED and specialty gas applications that depend on exceptional ultra high purity (UHP) gas quality. The DF-700 moisture analysers offer ‘exceptional’ accurate and repeatable performance, as well as proven reliability, affordability and ease of use. Servomex has also updated its DF-500 ultra-trace oxygen analyser range, again with performance-enhancing new firmware and an improved user interface. The DF-550E and DF-560E use a unique Coulometric E-sensor to measure down to 200 ppt (partsper-trillion) and 45 ppt respectively – the latter being the very lowest measurement available to the industry. Ever-smaller product footprints and ultra trace gas analysis are also significant trends in the analyser market, to which end Southland Sensing introduced a new OMD-580 microprocessorbased portable oxygen analyser for trace oxygen (O2) analysis in March 2015. The new analyser comes with a large colour display and user-friendly menu interface, along with a removable USB flash drive for data-logging.

“Ever-smaller product footprints and ultra trace gas analysis are also significant trends... As in so many aspects of the gases industry, and wider industry at large, automation is increasingly important to gas analysis and control technology. Larry Gallagher, CONCOA’s Specialty Gas Products Manager, told gasworld last year that the cost for automation, while perceived as too expensive five years ago, is acceptable and even cost-effective today – giving rise to its proliferation. He explained, “The trends that CONCOA has seen in technology, as it relates to gas controls, have been a movement toward more automation and real-time data and control than previously demanded. The human interface with main pressure controls

AGC – 50 YEARS OF GAS ANALYSIS AGC Instruments, based in Ireland, is celebrating its 50th anniversary this year as a leading manufacturer of total gas analysis solutions. The company was originally established in July 1965 to manufacture detectors (TCD) and entry-level gas chromatographs for the European market. Through natural development, the company extended these products into complete gas chromatograph and gas analyser solutions to meet the need of an expanding market sector. Now, as the company celebrates 50 years of business, AGC Instruments 18 | gasworld supplement | August 2015

offers a product portfolio ranging from gas chromatographs to modified atmosphere packaging (MAP) food gas analysers. AGC manufactures gas analysis solutions to all users requiring a quality control or identification of their gas stream, and has an increasing market share globally and in China in particular, following the opening of a new AGC Instruments China Sales & Support Office in 2009. Looking ahead, the company notes that, “The future is bright for AGC Instruments as the investment in research and development has led to an expanding

production schedule. As a result, more and more industrial installations globally have AGC products at the core of their quality control processes.”

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From cryogenic distribution and modern microbulk to related technologies and equipment, gasworld’s focus this September is on bulk gases – be sure to showcase your company’s credentials. Contact Ron Leitch: tel: +44 1872 225031 email: ron.leitch@gasworld.com

August 2015 | gasworld supplement | 19

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systems has been moving toward that interface through PLC, webbased or wireless communication.” “Operations that previously were face-to-face with manual or automatic switching devices by a trained staff are now trending to be handled by less skilled staff. What seems to be driving it is not just the information that can be derived from a pressure control device that monitors, stores and reports events and settings, but also from the shortage of experienced staff or the cost of experienced staff to manually manage gas systems.” Future growth In terms of future trends, the market for gas analysis will inevitably continue to follow the path of stability and repeatability of accuracy, ever-higher levels of accuracy, and factors of both portability and usability. Clearly automation will play an important role going forward. But future growth will also be spurred by the constant evolution of the markets and applications for gas sensing technologies. Consumption of gases – and therefore analytical products – in the food and beverages business, for example, is steadily increasing, gasworld understands. Further, compliance in food and drinks is constantly tightening and reviewed, placing demands on impurity monitoring and control. Shifts within the individual industrial gas markets themselves are also another example of evolving demands on analysers. As argon continues to replace more expensive and shortage-prone helium as the gas of choice for processes such as leak detection

“...compliance in food and drinks is constantly tightening and reviewed” and gas mixing and analysing, product manufacturers are required to adapt or introduce analysers to use argon accordingly. All of which makes for an increasingly competitive and progressive world of gas analysis and control technologies in 2015/16. gw

GAS2015: STRONG SHOWING CONTINUES AT GAS ANALYSIS EVENT The International Gas Analysis Symposium & Exhibition (GAS2015) once again drew a strong audience from the world of gas analysis and related equipment earlier this month. Held for the eighth time by NEN and ISO/TC 158 (Analysis of gases), the event attracted over 200 experts in gas analysis from 30 countries around the world. Sponsored primarily by Air Liquide, GAS2015 was held at the World Trade Centre Rotterdam in the Netherlands from 10th-12th June and focused on calibration gases, equipment, and the optimisation of industrial processes – combining science, standardisation and practical analytical techniques. The three-day event was officially opened by Michal Malicki from the European Space Agency (ESA), who gave two practical examples of gas analysis –

off-gas measurements of volatile organic compounds (VOCs) and CO2 – that occur during space missions. This was followed by parallel sessions on natural gas and biogas, metrology, standardisation and certification, analytical applications, and health, safety and the environment. The symposium programme consisted of almost 70 lectures across these parallel sessions, and around 40 poster presentations. Lectures were well received and provided input for discussion and gaining new ideas. The best lecture was awarded to Minami Amano from the National Metrology Institute of Japan. An exhibition floor with 26 participants was a convenient meeting and networking place during the breaks and opening drinks. Exhibitors included AGC Instruments, Air Liquide Specialty Gases,

Bronkhorst, DeMaCo, Inficon, The Linde Group, Tiger Optics, and V&F Analyse-und Messtechnik. Air Liquide was the event’s main sponsor, while fellow sponsors included Agilent Technologies and The Linde NETHERLANDS Group. Rotterdam

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20 | gasworld supplement | August 2015

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Process solutions for the products of tomorrow An interview with Martin Bender, Managing Director of WITT

ITT this year celebrates 70 years in gas analysis and control equipment, having begun with the launch of the world’s first dry flashback arrestor in 1945. Few, including founder Paul Witt, could have foreseen the company’s journey since then, transformed into the world-leading manufacturer of mixing, dosing, testing and analysis equipment that it is today. Here, as gasworld throws the spotlight of flow control and gas analysis equipment, Managing Director Martin Bender discusses the company’s celebrations, market trends, and why innovation – as well as flashback arrestors – are still at its core. GW: WITT recently celebrated 70 years in gas analysis and control. What can you tell us about WITT and what it stands for? MB: WITT is a manufacturer of gas-related equipment that meets the highest quality requirements. 70 years ago it began with flashback arrestors for cutting and welding. Today, we offer a complete range of reliable gas safety and control equipment including flashback arrestors and non-return valves, gas mixing and analysing systems, safety relief valves, pressure regulators, leak detection systems and much more. WITT products are manufactured exclusively in Germany. Modern production processes and comprehensive quality management systems guarantee the consistent achievement of the highest levels of safety and quality of everything that leaves our factory. As a premium brand, WITT complies with all relevant international and national standards. GW: What developments are underway at WITT in this special year for the company?

MB: WITT invests in research and development. New, trend-setting products are produced and existing ones are constantly upgraded. We have already launched – or are going to launch – a wide range of new products, like non-invasive oxygen (O2) analysers, new MEMS sensors for a faster and more precise measurement, and state-of-the-art remote controlled gas mixers. Thus, today WITT is already working on process solutions for the products of tomorrow. GW: What trends do you see in the world of gas analysis/control equipment and instrumentation? MB: The WITT development centre works closely with research institutes and customers. We see the trend towards more compact 22 | gasworld supplement | August 2015

and precise units at reasonable prices. Customers are also used to operating modern smartphones and expect the same handling from their industrial equipment. Touchscreen, NFC, WLAN are just some keywords, for example. GW: What challenges (and opportunities) do you see ahead in the gas analysis and control business? MB: Price is – and always was – an issue. So we are facing a quite fierce competition. The challenge is to offer reasonably priced products and at the same time, to remain a technology leader at this high quality level. On the other hand, there are many emerging markets related to the gas business offering good growth opportunities. They are looking for good-enough products, so it is important to find solutions that fit all markets.

“The challenge is to offer reasonably priced products and at the same time, to remain a technology leader at this high quality level” GW: What does the future hold for WITT as it embarks upon the next 70 years? MB: As a strong and healthy business, we want to grow further and still see opportunities in our core applications. At the same time we are looking for new, related applications that fit to our expertise. When Paul Witt founded his company in 1945 he could not foresee the amazing success of the business. In the past 70 years WITT has developed from a two-man business to a world market leader. Starting from cutting and welding, we now offer products for many different industries and applications: food and beverages, medical, laser, glass, renewable energies, diving, and many more. Relentless innovation was and is the base for our technology leading products, satisfied customers and corporate success. Nobody can make accurate predictions about the future, but our strength always was and still is to react to changes in the markets and to keep an open mind for new applications. With this high flexibility I’m very confident that we will be able to seize our chances and meet our targets. gw

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Cavagna Group SpA via Statale 11, 13, Ponte San Marco di Calcinato, BS, Italy, 25010 +39 030 9663 111 www.cavagnagroup.com The Cavagna Group™ offers the most complete and reliable line of products in the sector, supported by a never-ending commitment to research and engineering. We design, manufacture and distribute a wide range of valves and regulators for different types of high-pressure gas applications worldwide. From ultra high purity and medical care to industrial, welding and LPG applications, as well as alternative energy vehicles, fire extinguishing, cryogenics.

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