Fast-response, extended-range flow measurement.

Those responsible for the extraction, processing, storage, industrial plant distribution, consumption or sub metering of natural gas will find the latest advances in thermal mass flow measurement with Adaptive Sensing Technology™ (AST) from Fluid Components International (FCI) can help them achieve higher efficiencies at lower costs while reducing their carbon footprint to protect the planet and boost profits. 

The accurate, reliable measurement of natural gas is critical in a wide range of industrial processes and manufacturing applications. For example during oil extraction, refining, transport and storage, it is sometimes necessary to flare off excess gas at the wellhead, or later on during the separation process to remove water and contaminants, or aboard LNG vessels or at land-based storage facilities and distribution depots. 

Many manufacturing and processing industries, as well as large commercial buildings and campuses, also rely on natural gas as a fuel source to power boilers, burners, dryers, engines, furnaces, generators, kilns and more. Controlling natural gas costs is critical to product quality, competitiveness and profits. FCI’s green-friendly AST thermal flow meters help process and plant operation engineers in these industries conserve natural gas resources by measuring it more accurately and consistently with an innovative, patent-pending flow meter hybrid sensor drive. This measuring technique combines both of the industry’s highly proven constant power (CP) and constant temperature (CT) thermal dispersion sensing technologies in one flow meter. 

AST thermal flow meters measure in CT mode during start-up and through the lower flow ranges, and will then seamlessly shift into CP mode at mid-range and higher flow rates. The result is AST achieves a best of both technologies performance level to deliver extremely fast response with extended measuring ranges at low power consumption to maximize sensor reliability and reduce instrument energy expenses as well. 

FCI’s AST technology flow meters feature a rugged no-moving parts thermal flow element design, which provides direct mass flow measurement of air and gases with just a single process penetration. This approach saves plant real estate space and eliminates unnecessary installation labor, additional wiring and -MORE- other expenses. It also prevents the performance degradation encountered with other flow technologies, which require the addition of expensive temperature and pressure sensors to compute an inferred mass flow. 

With no moving parts to plug or foul, and virtually no pressure drop, AST thermal flow meters deliver extensive life cycle cost savings over higher maintenance technologies. The result is more accurate, repeatable mass flow measurement at the lowest total installed cost. In today’s complex process and manufacturing plant control schemes, AST thermal flow meters economically provide the accurate gas flow measurements essential for greater process consistency, quality, plant safety and environmental compliance. 

The FCI Model ST80 Series and the Model ST100 Series AST technology thermal mass air/gas flow meters are highly responsive (within 1 second) and accurate to ±0.75% of reading, ±0.5% of full scale, with repeatability of ±0.5% of reading. They are suitable for use in air/gas temperatures up to 850°F [450°C]. Their wide flow range, from 0.25 SFPS to 1000 SFPS [0.08 NMPS to 300 NMPS] and array of analog outputs and digital bus communications allow their application in almost any industrial process or manufacturing application. 

The Models ST80 and ST100 Series flow meters come with impressive global HazEx certifications for Div.1/Zone 1 level safety in the most demanding environments. Best-in-class integrated or remote displays feature full graphics and text with touch controls, offering flow rate or totalized flow data as well as sophisticated diagnostics.

Fluid Components International is a global company committed to meeting the needs of its customers through innovative solutions for the most challenging requirements for sensing, and measuring flow, pressure and temperature of air and gases.

#FluidComponents #FCI #PAuto #Gas

Flow in biogas applications.

Owners, operators and system designers of biogas production and recovery systems will want to explore the innovative ST80 Series thermal flow meter from Fluid Components International (FCI).

These users will find the new Model ST80 flow meter provides optimal performance and the necessary features required for accuracy and repeatability in demanding biogas flow measurement applications. The unit is an easy to install, safe biogas flow meter that delivers a truly best cost
solution.

In anaerobic digester produced biogas, for example, gas flow measurement can be challenged by the dirty, wet nature of this gas. Biogases are also a potentially explosive, mixed composition gas comprised primarily of methane (CH4) and carbon dioxide (CO2), with traces of hydrogen sulfide (H2S) and other gases that require stringent safety approvals to protect people, equipment and plants.

Furthermore, the residuals and particulates in the biogas, along with the H2S component, is a corrosive condensate that deposits itself on the pipe wall and instruments in the pipe, which can clog or foul orifice, vortex shedding, PD, turbine and most other technology sensors. The flow of rates of biogas varies widely too—based on fluctuating plant process demands and seasonal variations in temperature and humidity, requiring low flow sensitivity and wide turndowns.

Thermal mass flow meters using constant power technique, such as the ST80 Series, with their robust, open and cleanable, no-moving parts sensor design provide an ideal biogas application solution in this demanding environment. Furthermore, their international approvals for Div.1/Zone 1, on the entire instrument, ensure safe installation in hazardous biogas processing areas.

The measurement principle of thermal mass flow meters involves heat transfer caused by gas flow. Any moisture or condensate in the gas stream that intermittently contacts the sensors, however, can cause a sudden, momentary change in the heat transfer rate that can result in spiking or fluctuating readings.

Standard thermal flow meters using the constant temperature ∆T (CT) measuring technique are particularly reactive to moisture droplets, while constant power (CP) technique thermal meters, because of their slightly heated sensor that elevates the dew point, are less so.

The ST80 Series flow meter features FCI’s Adaptive Sensor Technology™ (AST™), which is an
innovative, patented hybrid sensor drive. This measuring technique combines, for the first time, both of the industry’s highly proven constant power (CP) and constant temperature (CT) thermal dispersion sensing technologies in the same instrument.

Complementing this new measurement drive technique are a choice of four different flow sensor element designs to further ensure best installed performance, including FCI’s new wet gas solution.

The Wet Gas MASSter™ sensor developed for the ST80 Series optimizes the sensor head design and installation to prevent condensation droplets, or rain, from contacting the sensors.

The ST80 Series flow meters are suitable for pipe diameters from 1 inch to 99 inches [25 mm to 2500 mm] and air/gas temperatures up to 850°F [454°C]. They feature accuracy of ±1% of reading, ±0.5% of full scale and repeatability of ±0.5% of reading with flow rates as low as 0.25 SFPS up to 1000 SFPS [0.07 NMPS to 305 NMPS] and 100:1 turndown.

This meter’s outputs and user interface choices are extensive to interface with virtually any control system and/or set-up or configuration devices. Standard outputs include dual, NAMUR NE43 compliant 4-20 mA analog outputs, HART (version 7), Modbus 485 and a USB port. Foundation Fieldbus or PROFIBUS PA or DP can be optionally added. The optional backlit LCD display provides digital and bar graph readouts of the flow rate and temperature, totalized flow, alarms, diagnostics feedback and even a user-defined label/tag field.

The ST80 Series transmitter enclosure is NEMA 4X/IP67 rated, selectable for NPT or metric
conduit port threading and is available in both aluminum and stainless steel and may be remotely located up to 1000 feet [305 m] apart from the flow element. The instrument also carries an independent, thirdparty evaluated SIL compliance.

#PAuto #FCI

True pioneering automation professionals honoured!

FCI Co-founders, Robert Deane and Malcolm McQueen along with the late Judy Stevenson of Magnetrol  were inducted into the Measurement, Control and Automation Hall of Fame during the MCAA Industry Forum last month in Atlanta.

Peter Martin, Chairman of MCAA and Vice President of Strategic Ventures at Schneider Electric introduced the honorees. Martin reminded the audience that 30-40 years ago our industry was focused on measurement and control instrumentation. Then the digital computer shifted the focus from measurement and control to the automation platform so that while there was still instrumentation, a lot of people were getting recognized for their work in automation based on the platform. However, he noted value doesn’t come from the platform: measurement and control instrumentation improve functionality in plants that drive profitability and, in fact, no one drives profitability more than our industry. Two years ago, the MCAA Board decided to recognize leaders in our industry that drive the value for our clients.

The Hall of Fame recognizes individuals whose body of work has contributed to the instrumentation and control industry in a significant and memorable way either through technical achievements, business accomplishments or industry leadership. Robert Deane, Malcolm McQueen and Judy Stevenson (posthumous) now join Gordon Arnold of Sierra Monitor, Wade Mattar of Schneider Electric/Foxboro and Dick Morley, all inducted in 2016.

Bob Deane

Bob Deane

Raised in Massachusetts, Bob Deane graduated from the Allen School of Aeronautics in Rhode Island and moved to California in 1954. There he worked in the aerospace and defense industries. Together with Malcolm (Mac) McQueen he founded Fluid Components International in 1964. He is the holder of three patents including the original thermal flow switch patent which helped launch FCI as a business. He also holds patents covering improvements to the thermal switch and a liquid-to-gas phase change detector. In the 1970’s FCI developed an air-to-gas flowmeter based on thermal dispersion technology. The company started a nuclear division in 1978 to deliver level, flow and temperature measurement to the nuclear power industry. He retired from FCI in 1995 but continues to work closely with the FCI engineers on specialized projects such as flow instrument applications and proprietary sensor packaging designs.

Malcolm McQueen

Mac McQueen

Malcolm ‘Mac’ McQueen received his Bachelor’s degree in Mechanical Engineering from the University of California, Los Angeles (UCLA). His early career was spent as a design engineer in the aerospace industry. It was then that he met Bob Deane who was working as an instrument sales representative. McQueen holds over 19 US and international patents involving flow applications. FCI has received the Control Global magazine Reader’s Choice award for thermal flowmeters and flow switches for the past 25 consecutive years. Although he retired in 1995, he has served as FCI Chairman Emeritus since 2000. Always an active philanthropist, he supported the YMCA and Boys and Girls Club. He was named Man of the Year by the San Marcos, California Chamber of Commerce and created a park behind the FCI plant for community events. In 2014 he established the Malcolm Murdoch McQueen Scholarship Fund for students pursuing a career in instrument engineering.

Mac McQueen accepted the honor on behalf of himself and his partner, Bob Deane who was unable to travel to the meeting. In his acceptance he noted that it was the confluence of a solid technology and trusting partnership that has made FCI a successful organization for the past 53 years. He called thermal dispersion mass flow measurement “seductively simple yet beguilingly complex”. He was proud to note the children (including his son, Dan McQueen, current President of FCI) have successfully taken over ownership and management of the company for over 20 years, and that the third generation is beginning to show interest. According to McQueen, FCI will continue to be a family owned operation for the foreseeable future.

Judy Stevenson

The Late Judy Stevenson

Judy Stevenson was inducted into the Hall of Fame posthumously. A family rule of “you must play the piano” led to her enrollment in piano lessons at North Central College. Her musical career was brilliant and she devoted herself to the clarinet, cello, chorus, band and orchestra while attending Naperville Community High School and continuing to North Central College where she studied voice and piano. She sang for two years with the Robert Shaw Chorale and performed with the Chicago Lyric Opera. But this was not the life-direction Judy Stevenson took. In 1964 she joined Magnetrol (then Schaub Engineering Company) as a part-time bookkeeper. In her first year of employment, she rose to accounting supervisor, then to accounting manager a year later. In 1967 she was elected treasurer and administrative vice president. She became president of the company in 1975 and in 1978–14 years after beginning in a part-time clerical position–Judy bought the company. Under her leadership, Magnetrol prospered due to an aggressive commitment to research and development, new products, new technologies, training and progressive and creative thinking. Today Magnetrol is a multi-million dollar company with over 800 associates in offices and manufacturing facilities worldwide. The company also attributes its success to its people-oriented culture and strong emphasis on the family–a reflection on Judy’s own beliefs. Judy established and endowed 11 college scholarships, six of which are awarded annually to the children of Magnetrol associates. She supported numerous local community programs and charities. Judy died at the age of 72 in 2010.

Craig Carroll, Vice President Sales - Americas for Magnetrol International, accepted the award on Ms. Stevenson’s behalf. He indicated that Judy’s story and the story of Magnetrol is one of passion, drive, commitment and determination. Judy sought and assumed leadership for what she could do for others. A well known philanthropist, there are many stories of how she applied personal attention to the people within her organization. She created a culture within the Magnetrol family of companies of ‘People come first’. She truly believed that people were the greatest asset of her organization.

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@MeasControl #PAuto @FCIflow @MagnetrolGlobal