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Deadline: 15 Feb 2019, 11.55pm

There are 15 different types of instruments listed here. In the same group assignment formed earlier, post here ONE case study relating to flow measurement. Your group may choose any instrument that would become the answer to your case study. Kindly state names of your group members and matrix numbers.

An example of case study is given below. The answer to that case study is ultrasonic flow meter. Your case study could be taken from books, websites etc. It could be original or modified case study.

Maximum allowable case studies for each instrument is FOUR ONLY. Once maximum limit is reached, you're not allowed to post there.

You're NOT allowed to repeat the same case study as posted earlier by other group.

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Case study : Coriolis Mass Flow Meter Multi-phase measurement in the upstream oil & gas industry 

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Case study : Coriolis Mass Flow Meter Multi-phase measurement in the upstream oil & gas industry 

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ANILSIA DAYUN ANAK MANG (55493)
FIONSHE ANAK THOMAS (56004)

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Eugene Tang (55900) Kelvin Lau Kuan Fei (56284)

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Eugene Tang (55900) Kelvin Lau Kuan Fei (56284)

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Case Study on Mag Meter solves intake water problem at Grupo Suzano Pulp & Paper Plant

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Case study: Usage of ultrasonic flow meter (Transmit-time flow meter) to improve the energy efficiency of water plant in university.

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Case study: Usage of ultrasonic flow meter (Transmit-time flow meter) to improve the energy efficiency of water plant in university.

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Vanessa Shaira anak Ngali (59239)
Felicity Deliastasia anak Robin (58612)
One university in Atlantic which has more than 60 buildings is considered as a green college. This university is ranked number 2 in the top 10 Greenest College Award by the Sierra Club. This university generates their own steam for heating and they have their own cooled water plants that helps to distribute water heated and cooled water supply throughout the campus. Back in the days this university uses turbine flow meter to monitor the flow of heated and cooled water supply through the campus. This device is such a hassle to use as all the flow data had to be entered manually by the operator. Furthermore, the turbine flow meter needed to be frequently calibrated and clean. This is because turbine flow meter is usually used to monitor a contamination free fluid. The management started to think of a better device to be use as they wanted to upgrade their energy management capability to achieve a more sustainable campus and maximizing and minimizing energy efficiency and carbon footprint of the university respectively.
After some research they found out that the most suitable flow measurement device to be used is ultrasonic flow meter. Their first choice of ultrasonic flowmeter needed a lot of maintenance too as they need to reapply the coupling gel to the transponder. This device relies on the gel to make acoustic contact between the transducer and the exterior of the pipe as the heat from the hot water will helps the gel to migrate from the contact area into the system. This shows that the device also relies on the temperature of the pipe which often give them inaccurate reading of flow measurement as the gels have a limited temperature tolerance.
The university team is searching for a more practical ultrasonic flow measurement solution to change the first ultrasonic flowmeter they used. They wanted a flowmeter that can provide them with an immediate data and helps them to maximize the energy efficiency. Turn out that the most suitable ultrasonic flow meter use is the one that uses the transit-time difference technique.
Transit time ultrasonic flow meter utilise the propagation time of the ultrasonic signal in the fluid. A pair of transducers are installed on the outer surface of the pipe. These transducers work alternately as emitters and receivers. Since these devices utilise ultrasonic propagation which can travel through solid thus it can be mounted outside the pipe and no cleaning is needed.
In conclusion, the transit time ultrasonic flowmeter is the most suitable device to monitor the flow heated and cooled water in throughout the campus. The usage of this device also helps to increase the energy efficiency of the water plant in the campus and become a more sustainable and greener university.

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Case Study: Advancements of Coriolis Meter to Improve Offshore Chemical Injection 	        Operations

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Case Study: Advancements of Coriolis Meter to Improve Offshore Chemical Injection 	        Operations

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Royce Anak Thompson (59146)
Esther Suling Edmond (58583)

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Case study: DESIGN ANALYSIS FOR A ROTAMETER USING CFD

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Case study: DESIGN ANALYSIS FOR A ROTAMETER USING CFD

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Nur Syazwanie Bt Ali (59023)
Siti Farha Bt Azhar (59184

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Case Study on Turbine flow meter in coffee machine

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Case Study on Turbine flow meter in coffee machine

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Muhammad Adhkhan Khawari bin Jusoh (58782)
Fakhrul Anwar bin Mohd Radiansah (55926)

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Case Study : Thermal Flow Meter Calibration For Natural Gas Service

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Case Study : Thermal Flow Meter Calibration For Natural Gas Service

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ISAAC BIN STEPHEN (59629)
PEREYLA ANAK TONY (57631

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Case Study : Simplex-Type pitot tubes for the measurement of water flow rate.

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Case Study : Simplex-Type pitot tubes for the measurement of water flow rate.

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MOHD NURUL IMAN BIN MOHD FOUZI (58761)
AKMAL KHUSAIRI BIN KARIM (55390)

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Group For 2:59054 Nurshada Nabiha binti Ibrahim, 59245 Wan Normardhiah Binti Wan 'Aizuddin

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Group For 2:59054 Nurshada Nabiha binti Ibrahim, 59245 Wan Normardhiah Binti Wan 'Aizuddin

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Coriolis flow

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Azzaiah Alphonsus Jenau Anak Steward (58504), Ria Pavia Anak Jelie (57707)

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Azzaiah Alphonsus Jenau Anak Steward (58504), Ria Pavia Anak Jelie (57707)

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Case Study (Nutating disc)
Addressing low-flow measurement challenges

Low-flow meters are designed to monitor and control very low liquid flow rates accurately, which can be problematic for traditional flow meters. Many industries rely on low-flow meters to ensure optimum liquid flow rates in batching, water separation, paint circulation, fuel measurement and chemical injection processes.
For example, a chemical injection system in the oil and gas industry uses low-flow meters to calculate the correct quantity of chemicals such as antifoaming inhibitor and methanol for injection into oil wells. Proper dosing of chemicals ensures efficient operation of the well system and increases productivity at minimal cost. Overdosing of chemical may results in excessive expenditure while underdosing may lead to underperformance of the well and premature maintenance may be required. Low-flow meters are essential to ensure proper dosage for accurate and cost-effective process operations. The most commonly selected meters for low-flow measurement are mechanical flowmeter with some type of moving part.
As an instrumentation engineer, identify an appropriate instrument that can be used to provide reliable doses of chemicals throughout the process. With the aid of diagrams, compare their working principles including the advantages and limitations.

Solution:
The appropriate instrument for the situation above is nutating disc flow meter which is one type of mechanical flowmeter.

Operating principle
1. The mechanism of a nutating disc flow meter comprises of a chamber which encloses a disc, a centre ball and a small pin. The disc and the small pin are integral to the centre ball where it is pivoted at the geometric centre. The disc’s position divides the chamber into compartments of an exact volume.
2.  Liquid pressure sets the disc in nutating motion. The law of conservation of mass states that the mass entering and leaving the system must be constant hence the quantity of water enters the inlet of the chamber will be expelled through the outlet. The compartments are filled and emptied every cycle.
3. The wobble motion of the disc/ball with small pin fastened on it result in a cone with the apex at geometric centre. This small pin converts the nutating motion of the ball into rotary motion of the shaft.
4. The shaft rotates the counter mechanism and each complete cycle can be calibrated in terms of volume of water received or discharged.

Advantages:
1. The downstream and upstream is less affected by the velocity profile.
2. Accurate measurement of consumption of fuel which helps to control fuel consumption.
3. Excel in measuring low-flow rate and high-viscosity liquids.
Limitations:
1. Viscosity of fluid flowing through them may affect the accuracy.
2. They are more appropriately used for clean fluids only.

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MOHD. AZFAR DANIAL BIN AZHARAN 50147
AWANG MOHAMED HAZIM BIN NORAJIKI 59985

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CASE STUDY : ULTRASONIC FLOW MEASUREMENT SOLVES REFINERY PIPELINE PROBLEM

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CASE STUDY : ULTRASONIC FLOW MEASUREMENT SOLVES REFINERY PIPELINE PROBLEM

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LOLIA AK JONATHAN JUA (56496)
BRENDA SANTIAGO AK PARIS (58513)

An Oklahoma refinery required a flow measurement solution for a finished gasoline and diesel fuel line leaving the refinery site. A Siemens clamp-on check meter and interface detector were used by them elsewhere on the site and the same solution on the fuel line was hoped to be installed. However, the local Siemens representative, the Ernie Graves Company, determined that there simply would not be enough straight run of pipe to support a clamp-on meter, and the refinery decided that they would need to bring the pipe above ground. Since the refinery was going to invest so much in altering the pipeline, the representative proposed that they choose a flow solution offering the same benefits as clamp-on technology, but with an even higher level of accuracy: the liquid version of the SITRANS FUT1010 ultrasonic flow meter.
The SITRANS FUT1010 was developed specifically for measurement of liquid and gas applications within the hydrocarbon industry, including pipeline, terminal, refinery and transportation applications. With the newly developed TransLoc mounting system, the transducers are permanently mounted on the outside of the sensor, providing custody-transfer accuracy while eliminating contact with the medium. To demonstrate the accuracy and repeatability of the SITRANS FUT1010, the liquid version was subjected to extensive tests at an accredited third-party test facility. The excellent results prove that the meter is a perfect match and a wise investment for the hydrocarbon industry.

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Case Study: Impact Of Pitot Tube Calibration On The Uncertainty Of Water Flow Rate Measurement.

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Case Study: Impact Of Pitot Tube Calibration On The Uncertainty Of Water Flow Rate Measurement.

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MUHAMMAD FITRI ADIB BIN NOORAZAMI (58811)
UTHMAN ARIFF BIN ZAHARUDDIN (59235)

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CASE STUDY: Refinery Cooling Water System Maintenance ProblemSolved With Hot-Tap Insertion Magnetic Flow Meter

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CASE STUDY: Refinery Cooling Water System Maintenance ProblemSolved With Hot-Tap Insertion Magnetic Flow Meter

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-MUHD ASHRAF BIN ANAWAR (56880)
-MUHAMMAD SHAHID BIN MANSOR
(58844)

Problem:
High-Maintenance full-bore Magnetic Meters Require Full Line Shutdown. The refinery’s full-bore electromagnetic flow meters supported flow measurement in both 36 and 42-inch water lines. The full-bore meters became dirty easily, leading to electronics drift
problems and unreliable measurement accuracy. The meters needed periodic cleaning,
which required shutting down the lines, removing the meters with heavy equipment crews, cleaning them and replacing parts as
necessary. The meters then had to be reinserted into the line followed by a re-start sequence for the line.
This maintenance process was cumbersome and expensive to ensure accurate meter readings with a high level of confidence. In
addition, the line shutdowns affected plant throughput productivity and impacted profits. In searching for a lower maintenance solution, the plant operations team contacted the applications group at McCrometer to discuss potential alternative flow metering solutions.

Solution:
After reviewing the application requirements, McCrometer recommended its full profile insertion multi-electrode magnetic meter. Designed to be installed (or removed and serviced) without shutting down or cutting the
line and without heavy equipment, the FPI Mag™ Flow Meter provides an exceptionally low installed and life-cycle cost. Hot tap insertion allows the flow meter to be
installed without interrupting service, dewatering lines, cutting pipe or welding flanges. The flow element can be removed from the line without shutting down water flow, cleaned, inspected, calibrated or verified with a simple process and then replaced without an expensive line shutdown and re-start sequence. Hot tappable, insertion-style flow meters such as
the FPI Mag that don’t require shutting down the line are cost-effective in the oil refining industry,
where production targets and profits are measured in the billions of gallons of refined product. This meter’s compact insertion design
with precision multi-electrode sensing and measuring technology fits extremely well into crowded plant retrofit or expansion projects. It also offers total accessibility without the need for heavy equipment and extensive manpower. Already low maintenance, this electromagnetic
meter is also packaged in heavy-duty 316 stainless steel for maximum structural integrity.
The sensor itself is coated with a 3M fusionbonded epoxy coating for operational longevity. With no moving parts and a single-piece design, the FPI Mag flow meter contains nothing to wear
or break and it is generally immune to clogging by grit or other debris. In addition, the flow sensor comes pre-calibrated from McCrometer’s
NIST traceable Calibration Lab and requires no recalibration in the field. In addition to forward measurement, this flow meter can be configured to provide bidirectional measurement, which is important in many applications. Bi-directional flow capability helps
users with complex, problematic piping configurations. Valuable flow data can now be gathered where measurement was previously cost prohibitive, such as areas affected by multiple expansions and retrofits or locations where two or more pipes converge and are consolidated into a single line.

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Aizatul Farzana Binti Salim (58427)
Nurashidah Binti Azman (59034)

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Case Study on Doppler Effect Ultrasonic Flow 

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Case Study on Doppler Effect Ultrasonic Flow 

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Nur Najihah bt Mohd Azhar 58994
Siti Shuhadah binti Shamsul Anuar 59203

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High Accuracy Pump Station Flow Monitoring Case Study

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Case Study on Flow Analysis of Positive Displacement Pump Lobe Rotor Using ANSYSWorkbench

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Case Study on Flow Analysis of Positive Displacement Pump Lobe Rotor Using ANSYSWorkbench

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Norsyafrizal Bin Amin 58922
Shahanim Syahirah Binti Khusrin Shah 57805

The rotary blowers are so rugged machines which are
noisy and inefficient in nature. In general, the noise
levels are more than 110 dB , and the efficiency is
less than 65% level. Moreover, the characteristic
curves run very steep (Figure 1.2) i.e., nearly
constant volume flow is produced over a wide range
of pressure ratio. Thus, to control the flow rates at the
same pressure ratio is difficult and requires design
changes in lobes/rotors profiles. To troubleshoot or
overcome these problems, measurements at plant site
or prototype test results through scale down
experiments at laboratory are not only complex task
in terms of money and time but also will not yield
expected flow characteristics that will aid to improve
performance of component. Alternatively, the flow
inside the rotary blower/pump also known as roots
blower can be obtained through computational fluid
dynamics techniques.

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Siti Nurkhaleeda Bt Muhammad Zabidi (59200)
Nur Adli Razali (57391)

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Electronic component assemblies often rely upon the application of very small quantities of solder or adhesive in precise locations. Precision machined dispensing needles and nozzles are used to accomplish this accurately. This tutorial examines the influence of nozzle design on blending separation in solder paste when dispensed under high pressure.

The Challenge：

Solving the problem of maintaining the right mix of solder paste during the dispensing processes.

This application required attaching electronic components on substrate circuits using solder paste. The paste must be placed at each attachment location in sufficient volume and blend to properly secure the die, and a good electrical connection while avoiding excess paste that could affect circuit performance. The process must be repeatable in high volume at a rapid pace.

Paste description: a mixture of solids (solder particles) and liquids (fluxes) which must remain blended in the correct proportions when dispensed out of the nozzle tip.

Paste mixture control: automated dispensing requires precise control of the pressure applied to push the paste out of the nozzle with the correct application at the right speed.

The correct application refers to the volume, shape, and blend of the paste. When solder paste is dispensed under high pressure, the differences in the coefficients of the resistance of the solids and liquids affect the flow rate. As they are pushed through the needle or nozzle blend separation can occur. This phenomenon leads to changes in the viscosity of the paste material that can clog the needle, causing inconsistent application amounts, and overall defective adhesion. This can cause a myriad of problems when mass producing electronic products.

The Solution:

Nozzles designed with an internal shape that minimizes flow interference and maintains consistent high flow rate with applied pressure.

The instantaneous changes in the mixing ratio of the adhesive paste material is affected by the dispensing pressure. The key to this approach was to analyze the dispensing pressure and develop a nozzle that would increase the flow of the material in order to reduce the unblending of the solder. This required that we improve the alignment of the nozzle intake to the dispenser syringe so that the pressure on the dispersant was evenly distributed with minimum back pressure. We also wanted the flow to be as frictionless as possible.

We succeeded in machining the interior of the nozzle to be the same diameter as the connecting syringe. By using a machining precision of only 0.001mm, we produced nozzles that eliminate separation due to differences in material flow.

Paste Dispensing data comparison of nozzle designs (application quantity and diameter)

Ratio of Solder Particle to Flux

The Design Rationale

The Result:

Increased the percentage of separating materials from 20% to 80%.

Separation of material in the syringe can now be contained by 80% as opposed to 20% previously. In terms of clogging, our nozzles can be used for a full day on average, saving a great deal of time and cost spent changing and cleaning nozzles. In conventional nozzles, separation would begin to occur after only 20% of the material was used in the syringe and would have to be later discarded with 40-50% of remaining material. Tecdia's precision nozzles are able to prevent separation and clogging, allowing more than 90% of the material to be used. This not only saves nozzle changing costs, but also material waste. The internal shape of the nozzles also makes cleaning more effective, saving time and cleaning solution.

Client Information

【Client Industries】
Manufacturing of electronic components for communications devices (mobile phones, and digital cameras etc...)

【Business Description】 Mobile phone/digital camera lens unit assembly (CCD/CMOS image sensors) and Crystal transmitter/crystal oscillators manufacturing

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Nozzles for Highly Controlled Dispensing

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Electronic component assemblies often rely upon the application of very small quantities of solder or adhesive in precise locations. Precision machined dispensing needles and nozzles are used to accomplish this accurately. This tutorial examines the influence of nozzle design on blending separation in solder paste when dispensed under high pressure.

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Case Study: A study of the superficial palmar arteries using the Doppler Ultrasonic Flowmeter

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Case Study: A study of the superficial palmar arteries using the Doppler Ultrasonic Flowmeter

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Mohd Harith Bin Ramzi (58751)
Maziz Syafiq Bin Mujib (58704)

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Barbra Basy Anak Cassidy Gundi (58505)
Emily Rinta Anak Lembang (58575)

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Case Study: Thermal Mass Flow MonitorsMethane Emissions

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Case Study: Thermal Mass Flow MonitorsMethane Emissions

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Muhammad Nazril Hafiz Bin Saidatul Nizam (58836)
Zul Zaffri Bin Mustafa (59260)

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54-245.0 Case Study-Monitoring Methane Emissions

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Monalisa Johadin@Alung 58767
Erra Nadzira Binti Hasnan 55893

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Nur Syahirah binti Salimin (59016)
Nurul Fastifa binti Ab Sani (59085)

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Case study on Vortex Flow Meter performance

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Case study on Vortex Flow Meter performance

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Muhammad Yazid Bin Mohamad Fuad (58852)
Mohd Fadzil Niza Bin Abang (5932

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Vortex flow meter performance case study

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Case Study on Ultrasonic Transit-Time Flow Meter of Global Water Instrumentation

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Case Study on Ultrasonic Transit-Time Flow Meter of Global Water Instrumentation

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Marilyne Undart Anak Martin Alling (56559)
Melissa Jane Anak Andrew (56592)

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Transit time flow meters case study at groundwater remediation site.

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Walter Xavier Anak Ngadan 58246
Jacquelyn Mujan Jok 56179

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Case Study On Transit-Time Ultrasonic Flow Meter of Golf Course Irrigation

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Case Study On Transit-Time Ultrasonic Flow Meter of Golf Course Irrigation

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Evyceonna Ida anak Jilom (58586)

Nur Sahira binti Abang Abdul Khaled (59002)

Summerheights Golf Links in Cornwall, Ontario draws irrigation water from the South Raisin River. Flow rates in the river can become very low during dry periods so water extraction is regulated and monitored closely.

Under a water extraction permit issued by the Ministry of The Environment in 2009, the golf course is allowed to draw a maximum of 500,000 liters per day at a flow rate not to exceed 1,380 liters per minute (and 600,000 liters per day at max 1660 liters per minute after July 1st each year).

To measure and control water pumped into the sprinkler system, a Greyline TTFM 1.0 Transit Time Flowmeter with clamp-on ultrasonic sensors was installed on the outside of the main 6" steel pipe from their pump station. A Rain Bird® control system then manages water distribution to each sprinkler head.

Transit time ultrasonic flow meter measure the difference in time from when an ultrasonic signal is transmitted from the first transducer until it crosses the pipe and is received by the second transducer. A pair of the transducer is installed on the outer side of the pipe. The ultrasonic signal must transverse the pipe to be received by the sensor. When the ultrasonic signal is transmitted towards the upstream against the flow direction, the propagation time requirement is longer and oppositely for the transmission towards downstream side as the propagation time is less.

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Case Studies: Structural Health Monitoring for Real-Time Asset Management of Small Bridges

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Case Studies: Structural Health Monitoring for Real-Time Asset Management of Small Bridges

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Dina Dzuremilia Binti Asan (58556)
Nur Afiqah Binti Mohamad Malek (58929)

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Clearance Analysis and Leakage Flow CFD Model of a Two-Lobe Multi-Re-compression Heater

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Clearance Analysis and Leakage Flow CFD Model of a Two-Lobe Multi-Re-compression Heater

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Christopher Joyle Indor (55745)
Petrus Gabriel anak Dana (59118)

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Clearance Analysis and Leakage Flow CFD Model of a Two-Lobe Multi-Recompression Heater

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Rotary lobe pumps with FPM lobes: Disposal and recycling of used oils

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Rotary lobe pumps with FPM lobes: Disposal and recycling of used oils

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Oliver Yii Chii Sing (57595)
Gan Yi Jiunn (56034)

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Case Study_ Rotary lobe pumps with FPM lobes - KS-Recycling GmbH _ Vogelsang

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Affy Maxmiano Anak Junih (55324)

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David Alvin anak Patrick(58537) Mohd Azri Bin Roslan(58744)

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David Alvin anak Patrick(58537) Mohd Azri Bin Roslan(58744)

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The Lion Air jet that crashed into the Java Sea off Indonesia earlier this week had experienced problems with the sensors used to calculate altitude and speed on its previous flight, an issue that could help explain why the plane dove into the water.

Pilots on the nearly new Boeing Co. 737 Max reported the issue after flying from Denpasar to Jakarta the night before the accident, Lion Air spokesman Danang Mandala Prihantoro said Wednesday. The instruments were checked by maintenance workers overnight and the plane was cleared to fly, Prihantoro said.

While it will be days or weeks before definitive information emerges in the crash shortly after takeoff with 189 people aboard, discrepancies in speed and altitude readings can cause confusion on the cockpit and have led to accidents in the past, including the 2009 crash of an Air France plane in the Atlantic Ocean.

Flight-tracking data before the Lion Air crash showed the plane was varying its altitude and speed, a possible indication that the pilots weren’t getting accurate information from the aircraft’s air-pressure sensors.

Erroneous sensors could be an explanation for the flight track data, said John Cox, president of Safety Operating Systems and a former airline pilot. But Cox and others cautioned that it’s too soon to say what happened on the Lion Air flight and some of the flight data — such as speeds that weren’t extreme and none of the highly abrupt maneuvers that preceded the Air France jet’s loss of control — may suggest some other cause.

Indonesia’s National Search and Rescue Agency hopes to find the plane’s crash-proof flight recorders and the main wreckage of Flight JT610 on Wednesday night, said M. Syaugi, head of the agency.

Search teams have picked up sound signals from the so-called pingers attached to the recorders, which activate when they come in contact with water to make them easier to locate, Syaugi said.

Search and rescue teams are confident they have located jet’s fuselage, National Military Chief Hadi Tjahjanto said.

“We have located the area where we strongly believe the plane’s black box is located. The large parts of the aircraft should be nearby,” Tjahjanto said.

Even with modern GPS tracking, planes need to calculate their precise speed through the air. To determine airspeed — which can vary substantially compared to the speed over the ground due to winds — aircraft rely on pitot tubes, which measure the air rushing into them.

By comparing that pressure against the ambient air pressure — which is obtained by what are known as static ports — aircraft can determine airspeed.

If either of the pressure sensors are blocked, it can cause erroneous readings. In the case of the Air France flight, investigators concluded that a high-altitude ice storm clogged the pitot tubes.

Modern jetliners are equipped with three separate airspeed sensor systems as backups. If one goes bad, pilots are trained to check the other readings and disregard the one that’s incorrect.

Lion Air and investigators haven’t provided details about the issue on the previous flight Sunday night. Data provided by flight tracking company FlightRadar24 showed that the jet took off and reached an altitude of 5,550 feet (1,692 meters), then dropped to 4,625 feet, an unusual altitude loss at a time when aircraft normally climb steadily.

The plane then resumed its climb, but never climbed above 28,000 feet. Jetliners almost never fly below 30,000 feet because cruising at the lower altitudes is less fuel efficient. However, planes with partially malfunctioning altitude sensors aren’t allowed above 28,000 feet.

“Every aircraft that we have will go through transit, pre-flight and post-flight checks,” said Lion Air’s Prihantoro. “We are conducting inspection and maintenance if needed on every aircraft.”

United Technologies Corp. is a supplier of the systems to the 737 Max, according to Airframer.com, a website that tracks suppliers of aircraft components. A company representative said she wasn’t immediately able to confirm whether its equipment was on the Lion Air plane.

Indonesia’s National Transportation Safety Committee, which is leading the investigation, has interviewed pilots from the previous flight, Ony Soerjo Wibowo, an investigator, told a news conference on Tuesday.

In the Air France accident, investigators concluded that the pitot tubes had become clogged with ice and all three of the plane’s speed indicators failed at different times, according to the final report of France’s Office of Investigation and Analysis.

The routine flight from Rio de Janeiro to Paris was interrupted with a cacophony of alarms and confusing information. Their autopilot disconnected, speed indicators went haywire and warnings sounded indicating they were going too slow. “We haven’t got a good display,” one of the pilots said, according to the accident report.

Completely flummoxed, the pilots abruptly climbed and then lost control, allowing the plane to plunge for about four minutes until it slammed into the water.

While such failures happen fairly frequently and pilots should be able to continue flying the plane until the problem resolves itself, a handful of airline accidents such as the Air France crash show they can be confusing if pilots are startled and don’t react properly.

A charter flight leaving the Dominican Republic in 1996 crashed, killing 189 people, after the captain’s airspeed became inaccurate. While it was never proven, a wasp’s nest in the pitot tube was suspected as the reason for the error.

An Aeroperu flight that crashed in 1996, killing 70, was blamed by the Peruvian government on tape that had been left over the static ports. Shortly after takeoff, pilots received nearly simultaneous cockpit warnings that they were going too fast, too slow and too close to the ground, according to the investigation.

While it’s too early to know if airspeed indicators will prove to be related to Monday’s accident, the possibility underscores the need for better and more consistent pilot training, said David Greenberg, an industry consultant and former operations executive at Delta Air Lines Inc.

Greenberg, who also served as chief operating officer at Korean Air Lines Co. Ltd., said U.S. airlines drill pilots for such contingencies in the classroom and flight simulators.

Partially as a result of the Air France crash, the U.S. Federal Aviation Administration in recent years revamped pilot training for how to handle unusual speeds and cases in which the plane goes out of control. It’s now common for airline pilots to receive simulator training on how to handle a failure of the plane’s speed indicators.

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Case Study: Modelling and Simulation of a Thermal Mass Flow Sensor for determining the flow speed and thermal properties of binary gas mixtures

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Case Study: Modelling and Simulation of a Thermal Mass Flow Sensor for determining the flow speed and thermal properties of binary gas mixtures

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AMIRUL AMIEN BIN ARIFIN (58450)
ALYSSA ASONG ANANTHAN (55430)

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Yong Tze Jack (58354)     Hong Wei Hao (56124)

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Yong Tze Jack (58354)     Hong Wei Hao (56124)

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Case study on Mag Meter Solves Tight Installation Challenge

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Case Study: Coriolis mass flow metering for wet gas.

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Case Study: Coriolis mass flow metering for wet gas.

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Ismul A'zam Bin Hisam (58663)
Luqman Hakim Bin Mat Fouad (58691

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Ngo Fang Jun (56943)
Yii Seng Lung (58344)
A major printer based in Chicago, Illinois uses hundreds of Type S High Pressure meters to measure offset printing ink to printing presses. Ink is very expensive and must be measured accurately. The Nutating Disc Type S High Pressure Meter provides the accuracy and cost control that this printer and many others require in their processes. The Neptune Type S Nutating Disc High Pressure (HP) Flowmeters are precision-constructed measuring instruments used for accurate measurement of liquids at high pressures. The dual case measuring chamber design means accuracy does not change with increased fluid pressures.
Type S High Pressure Meter Features

Heavy duty design withstands high pressure

Simple in design and easy to service

Standard NPT fittings for easy installation

Compact design

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Case study: Dual Vortex Flowmeter Increases Performance of Ethylene Cracker in Petrochemical Company

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Case study: Dual Vortex Flowmeter Increases Performance of Ethylene Cracker in Petrochemical Company

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Lucas Chai Kim Hong 56518
Chua Hui Leng 55748

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Case Study: The Effect of Turbulence on a Multi-Hole Pitot Calibration.

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Case Study: The Effect of Turbulence on a Multi-Hole Pitot Calibration.

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1.Abang Ahmad Dzulfakhri Bin Abang Hastanal Madani (58385)
2.Mohd Nur Azmeer Bin Made (58760)

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Case Study: Oil Flow rate monitoring in Carpet Ovens

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Case Study: Oil Flow rate monitoring in Carpet Ovens

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George Luang Anak Jenggut 58619
Maximillian Guang Anak Manggas 58702

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Oil Flow rate monitoring in Carpet Ovens

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Richard Chin Kai Yu 57710 & Rachel Chai Sze Chi 57671

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Richard Chin Kai Yu 57710 & Rachel Chai Sze Chi 57671

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On the premises of a local company in the greater Frankfurt area, which deals with the production of hygienic and cosmetic products for human application, a part of the production needed to be expanded and renovated for economic reasons. However, we don’t always have the best conditions for such conversions. And in this case, due to reasons related to technical production processes and local conditions, the underground storage tanks for isopropanol and ethanol, with a medium temperature of about 7ᵒC, were about 400 m away from the planned filling stations.

The products that need to be filled must be taken to various pipelines at five separate filling station. These pipes are situated only on a part of its total length in various temperatures, so depending on the weather, greater temperature differences may occur. The product freezing is not a concern, however, there may be larger variations in the density of the fluids. The possibility of trace heating and heated pipelines is excluded completely for energy-related aspects and by the company’s philosophy, which focuses on the environment and sustainable economy.

The planning and construction of the facility is to be designed so that the used materials meet safety requirements, accuracy, hygienic standards as well as the economic aspects and durability.

Solution:
A suitable flow meter system is nutating disc flow meter. Since hygienic requirement is a great concern, stainless steel nutating disc is required. However, the negative vote for this flow meter is that it is a volumetric meter and cannot measure mass flow accurately when there is a variation of temperature. Hence  a PT100 temperature gauge can be installed and connected to a programmable logic controller. This setup can accurately calculate the mass flow rate by introducing a calibration factor to the volume flow rate by using the temperature measured. This metering solution is about 80 % cheaper and therefore unbeatable.

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Case Study on Mag Meter helps with Non-Revenue Water

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Case Study on Mag Meter helps with Non-Revenue Water

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IHSAN ZIKRULLAH BIN MOHD AMIN (58650)
NURAZIZUL HISHAM BIN NUZULFIKAR RAZEEF (59036)

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Rotameter- Investigation of flow in rotameter

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Rotameter- Investigation of flow in rotameter

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Allan Pui Fui Ching (59268)
Tan Chuan Ser (58062)

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Case study: Thermal Mass Flow Meter Delivers

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Case study: Thermal Mass Flow Meter Delivers

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DOMION DING TOM (58557)
FRANKLIN LINGGA ANAK ABUN (58616)

Background

Guohua Ninghai Power Plant is located at south of Shanghai in Ninghai township. Ningbo city, Zhejiang province and serves the electric power needs in the region. The plant’s large production operations are complex. Coal is first fed from silos at the plant to coal mill pulverizers, which grind the coal into a fine powder. A fan blends and forces a primary flow of mixed ambient “cold” air and pre-heated “hot” air into the coal mill. This air is mixed with the coal powder creating a combustion air supply for a furnace heating water in a boiler. The boiler produces steam to drive power-generating turbines. The plant’s sophisticated, energy efficient boiler requires accurate and responsive air flow measurement for its control system.

Problem

The boiler’s steam production efficiency is controlled by adjusting a precise flow of blended primary ambient air and pre-heated air which flow from separate ducts. Each of the duct air flows is controlled by louvered dampers located inside the ducts. The primary air, which is a precise blend of cold and hot air, flows into the coal mills and afterwards the boiler. Accurate, responsive and reliable air flow measurement is critical to the automated control of the dampers and the efficiency of the boiler, which also ensures safe operation of the boiler and reduces plant operation energy costs.

Solution

By considering the applications and criteria needed for the flow meter, which are the accuracy and responsive performance and the overall suitability for the unique application conditions in the air feed lines, thermal mass flow meter is the most suitable.

These precision air flow meters are installed and operating around the world in numerous electric power generation plants in similar applications because they are accurate, stable and reliable flow measurement over wide temperatures and variable pressures. These sensors can be installed along a single probe assembly or on multiple probes, whatever is optimal for the application and installation conditions.

Thermal mass flow meter also suitable for large diameter pipes or large duct applications that usually be found at thermal electric power generation and other heavy process or manufacturing industries. It provides excellent air and gas flow measurement performance in applications such as these coal-fired combustion air systems as well as in HVAC systems, flues, and stacks.

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Case Study: Investigating water meter performance in developingcountries: A case study of Kampala, Uganda

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Case Study: Investigating water meter performance in developingcountries: A case study of Kampala, Uganda

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Cheryl Rinai Raja (58527)
Zul Farra Ain Binti Misman (59259)

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Rotating vane flow meter case study within the medical field (anasthetic)

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Rotating vane flow meter case study within the medical field (anasthetic)

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Shawn Iannu anak Guillan (57832)
Elister louis Anak Dampa (55861)

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Effects of Xenon on the Performance of Various Respiratory Flowmeters

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(Goto) Associate Professor, Teikyo University Ichihara Hospital. (Saito) Chief Medical Engineer, Department of Medical Engineering, Teikyo University, Ichihara Hospital. (Nakata, Uezono, Ichinose) Assistant Professor, Teikyo University Ichihara Hospital. (Uchiyama) Associate Professor, Department of Anesthesiology, Nihon University, School of Medicine. (Morita) Professor and Chairman, Department of Anesthesia, Teikyo University Ichihara Hospital.

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Rotating vane flow meter case study within the medical field

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Rotating vane flow meter case study within the medical field

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Development length and mass measurement on conveyor belt

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Development length and mass measurement on conveyor belt

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CHIN JING KEY (55689) & MAGRET  IPAH  ANAK JUNI (56527)

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Case Study : Improving The Conveyor Belt Lifetime

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Case Study : Improving The Conveyor Belt Lifetime

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JIOVANNY ANAK JUTIM (56219)
AKRIMI MISWA BT ABDULLAH (45442)

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Case Study on rotating vane flow meter within domestic and industrial water consumption, petroleum and gas, food industries.

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Case Study on rotating vane flow meter within domestic and industrial water consumption, petroleum and gas, food industries.

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http://infohost.nmt.edu/~petro/faculty/Nguyen/PE424L/L3_FlowMetering.pdf

Estefan Othniel Lisut 55897
Jonathan anak Peter Giman 56229

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Case study on Doppler effect Ultrasonic Flow

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Case study on Doppler effect Ultrasonic Flow

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Lim Fook Syn 56434
Suman Das 59425

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Monitoring High Flow in Large Channels Case Study

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Choo Yun Jian 55732
Ng Ji Wei 56931

In this case study, it is about the precision flow measurement in the brewing industry. From the journal, we are focusing in the lobed impeller flow meter. It is one of the oldest flow meters that apply in the industry. However, it is still having high accuracy and repeatability if it is designed according to high quality standard. There are two type of versions where the older version is driven by gears and registers whereas the modern version is installed with electronic transmitters in order to reduce the moveable part (reduce maintenance cost). Newer version is also being developed to suite the usage of this type meter in the brewing industry with high accuracy. In conclusion, lobed impeller glow meter will give high accuracy result in brewing industry.

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Case Study: How a Capped Edge Conveyor Belt Helped A Vegetable Supplier Cut Costs 

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Case Study: How a Capped Edge Conveyor Belt Helped A Vegetable Supplier Cut Costs 

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Mohd Laji Bin Sumarno (58754) Muhammad Ilman Hanif Bin Mohd Sarif (58822)

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Rotating Vane Flow meter Application for anesthetic Xenon

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Rotating Vane Flow meter Application for anesthetic Xenon

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Probal Roy (59422)
Tamjidur Rahman (60068)

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Case study: Nakilat keppel offshore and marine shipyard was repairing the ship on the dry dock. After repairing the propeller shaft during sea trial, the shaft was found little bend cause the alignment was not correct. And before starting the sea trail they did not used the strain gauge.

Solution: When the ship arrives on the dry dock the ship yard foreman should take the propeller shaft bearing Clearance and strain gauge reading then they keep this record and hand over to the chief engineer. After completing the job, they give the same strain gauge reading and correct alignment to chief engineer in order to avoid shaft bending. Fields of application Strain gauge modelling/measuring is used in both new building and maintenance / repair. The technique is used in both 2-stroke as 4-stroke installations. The strain gauges are carefully glued to the propeller shaft in pre-defined positions (nr of gauges depend on the installation). The gauges are connected to a device that measures the change in resistance when the shaft is turned 180⁰. This change in resistance can be entered the model and the actual horizontal and vertical alignment can be determined. Comparison to manufacturer’s alignment instruction results in the needed adjustment of component(s). When the theoretical model is prepared before the scheduled maintenance, the repair period can be as short as possible.

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RAYNOLD ANAK NIGEL(55002)

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A premier winery in Napa Valley contacted BETE to help improve their tank cleaning process. They had tried both rotating tank wash machines and traditional static spray balls, but they weren't satisfied with either option. Even with a preliminary rinse before the cleaning process, leftover grape debris in the fermentation tanks such as seeds, stems, and skins found its way into the nozzles during recirculation cleaning cycles

Problem: Incomplete Coverage during Tank Cleaning

The solids in the fermentation tanks would jam rotating tank wash nozzles, resulting in incomplete coverage which is detrimental to the winemaking process and difficult to detect from outside of the tank. Static spray balls, on the other hand, have no moving parts but feature many small orifices that are prone to plugging, also resulting in incomplete coverage. With both options, the amount of maintenance time required to keep the nozzles in proper working condition was unacceptable.

Solution: The BETE HydroClaw®

BETE engineers went to work to develop a solution to this issue that plagues not only the winemaking industry, but also brewing, food processing, and many other applications that involve cleaning tanks with high solids content. The result was the new HydroClaw nozzle with a full 360-degree spray pattern, three times the free passage of a comparable static spray ball, and no moving parts to jam.

Results

After a trial of the unit, the customer was so pleased with the cleaning performance and clog resistance of the HydroClaw that they used it exclusively to clean their tanks during the busy harvest crush season, the time when the fermentation tanks experience their highest levels of solids. Over the course of several months, they did not suffer a single clogging issue.

Additionally, the high flow rate of the HydroClaw allowed the customer to adequately pre‐rinse their tanks using quick and powerful blasts of water, reducing their overall water consumption compared to a low flow nozzle operating for a more extended period.

Challenges with Static Spray Balls

Clogging

Extended maintenance time

Incomplete tank coverage

Excessive water consumption

Advantages of The BETE HydroClaw®

3X the free passage of static spray ball

360-degree coverage with no moving parts

High flow rate provides vigorous rinsing action to flush tank solids and contamination quickly

Sanitary finish for food and beverage applications

Saves you time AND money

The HydroClaw was explicitly designed to provide wineries a tank washing solution that permits stems, skins and seeds to flow through the nozzle. This configuration makes it the ideal nozzle for food processing operations.
Whether used in winemaking or another type of food processing plant, the HydroClaw provides full coverage, reduces downtime for maintenance, lessens water usage, and saves money and time.

Why Choose BETE for Your Beverage Industry Nozzle Needs?

Partner with a nozzle leader with over 65 years of solving nozzle challenges

ISO 9001:2015 Certified

Dependable quality assurance in design and manufacturing

Experienced in custom applications replacing static spray balls with superior nozzle solutions

At BETE, our experience gives you outstanding customer support and an exceptional product.
To discuss your fluid-related challenge, please contact BETE Applications Engineering at 413-772-0846 or appeng@bete.com.

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Static Spray Ball Vs HydroClaw | Winery Spray Nozzle Case Study

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A premier winery in Napa Valley contacted BETE to help improve their tank cleaning process. They had tried both rotating tank wash machines and traditional static spray balls, but they weren't satisfied with either option.

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Alexander Kuleh Paul (55401)
Mahendra Suhartono Suwandhi (59406)

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Case study on radiant-based instrument conveyor belt

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Case study on radiant-based instrument conveyor belt

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Joana  Anak Peter (56220)
Alvin Tingai Thomas (55427)

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Case study on the Application of Conveyor belt

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Rotameters (variable area) for compressed air flow metering

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Rotameters (variable area) for compressed air flow metering

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Nur Nasuha Binti Sani (50802)
Syafiqah Zulaikha Binti Sharkawi Shawal (55081

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Measuring flow when the fluid is compressed air or other gas presents a different set of challenges than liquid, due to the fact that volume changes with pressure. To avoid that issue, air and gas flow is typically measured in SCFM (standard cubic feet per minute) rather than ACFM (actual cubic feet minute). Flowmeters that measure the mass of gas solve this issue easily, but they are generally expensive instruments. Rotameters (aka, variable area flowmeters) provide a gas flow measuring technology that is simple, inexpensive and relatively accurate, but they can get you into trouble if you don't know how to interpret what they say.

If you aren't familiar with the technology, Rotameters use a float inside a tube that has a tapered bore with its largest diameter at the top. They are mounted vertically with the inlet at the bottom and the outlet at the top. (Some designs use a spring loaded float that can be mounted in any position.) Air (or other gas) flowing up the tube will lift the float until it reaches the point where the annulus around the float is large enough that the gas can move around the float without raising it any higher. The tubes are normally clear so you can see the float, and a scale is attached to determine the reading. They use a visual indication, but can be outfitted with accessories to provide electronic reading options.

Rotameters generate their reading according to velocity through the tube, which is more a function of volume, not mass. So, if the pressure of the gas going through the meter increases, the volume measured in SCFM also increases, even though the float is in the same position and gives the same reading. This is where things get tricky and you have to know what you're dealing with.

If you want your reading in SCFM and the air is compressed to some extent, you have to keep some simple things in mind.

First, you should install pressure gages at the inlet and outlet of the Rotameter. There will be a pressure drop across the device, and it is important to know the pressure at both ends.

Second, choose your scale carefully: Some manufacturers have a complex scale that is actually a chart with curves indexed for various pressures. When reading the meter, you have to follow the curve to the correct pressure point for the true flow reading at that pressure. These scales are handy and can operate over a wide range, as long as the operator reads them correctly.

A meter that has a single generic scale will need to be manually corrected. Most flowmeters are based on atmospheric pressure, so any deviation from that will require correction. Your vendor should be able to supply you a formula that will tell you how to calculate the true SCFM reading based on the operating pressure. Usually this involves the reading at the inlet, which is why you need both gages.

If you plan on using the meter for a specific set of conditions, some vendors will make you a custom scale to give a correct reading at that pressure. E.g., if you have an application that always operates at 40 psi (measured downstream of the meter), the vendor can make the unit specifically for that pressure. As long as you stay with that pressure, you will have proper readings. If you move off that pressure, you will have to calculate a correction, andthe vendor should provide you the formula for that.

While this may sound like a lot of trouble, bear in mind that Rotameters can be reasonably accurate (

You can also search online at Control Engineering Supplier .

-Peter Welander, process industries editor, PWelander@cfemedia.com ,
Control Engineering Weekly News
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Tutorial: Rotameters (variable area) for compressed air flow metering - Control Engineering

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Measuring flow when the fluid is compressed air or other gas presents a different set of challenges than liquid, due to the fact that volume changes with pressure. To avoid that issue, air and gas flow is typically measured in SCFM (standard cubic feet per minute) rather than ACFM (actual cubic feet minute).

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Raja Nurul Amira Bt Raja Jamam (50905)
ZULAIKHA BINTI HAMDAN 54309

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Gloria Elaine John (58623)
Nova De Claudia Tay (58923)

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Case study using clamp on transit time ultrasonic flowmeter for accurate helium measurement

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Case study using clamp on transit time ultrasonic flowmeter for accurate helium measurement

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Standley anak james(57994)
Giri anak jamar(56045)

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The portable ultrasonic flowmter accurately measures flow at even the slowest rates.
(Photo courtesy of FLEXIM AMERICAS Corp.)

Since 1996 the demand for helium has been ramping up, as supply remains fairly static. Accordingly, prices have risen sharply. For example, in 2014 the price for crude helium is estimated to increase 30 percent.

The culprit? The Federal Government in the guise of the Bureau of Land Management (BLM).

The danger? Helium is much, much more important than party balloons and parades.

The solution? More private production and storage facilities, but those are some years away.

In the meantime? Conservation using accurate flow measurement to assure maximum efficiency and minimum waste. This is critical because there is a finite amount of helium available, and when it leaks into the atmosphere it rises and releases into space.

Properties of Helium
The helium atom is smaller than that of any other element and second only to the hydrogen atom in lightness. As a result, helium is chemically inert and does not form stable compounds with other elements. The attractive forces between helium atoms are also so weak that helium has the lowest liquefaction temperature of all the permanent gases and, unlike all other elements, does not freeze under its own vapor pressure as the temperature is lowered toward absolute zero. Helium turns to liquid at -268.93 C. Absolute zero is -270 C, making helium the very best element for super-conducting applications.

The Federal Reserve
The first large-scale use of helium for nonscientific purposes was its substitution for hydrogen as a lifting gas in lighter-than-air applications (e.g., dirigibles, zeppelins, and blimps). Even though hydrogen provides about 7 percent more lift than helium, it is much more dangerous to use because it is highly flammable. The military importance of helium as a lift gas in the early 20th century led to the development of the Federal Helium Reserve in 1925.

Losing Money
By 1995 the reserve was $1.4 billion in debt as a result of earlier purchases of helium from private producers and their practice of selling helium below market rates. The debt was due to finally be repaid to the U.S. Treasury Department by the fall of 2013 and, under current law, funding to the federal program would then stop, terminating operations. The BLM assumed market forces would move in to fill the gap. That happened, but at a much slower rate than was anticipated. The anticipated closing of the Bush Dome would have a significant impact on numerous industries throughout the world-everything that uses computer chips, MRI machines, aerospace, super cooling, and scientific research. That meant that the cost of many things would rise dramatically.

A Solution-Kind Of
Fortunately, Congress acted and in September 2013 passed the Helium Stewardship Act that keeps the reserve going and provides a formula that gives guidelines for pricing relative to current market prices.

The problem was that helium prices were at an all-time high. Helium refiners had already been raising prices in anticipation of the Bush Dome's closure. There were other helium plants and storage facilities in the works, but their completion and production were still years away. There was no choice but for businesses to find ways to conserve and learn to work smarter.

READ ALSO: Clamp-On Ultrasonic Flowmeters Get Another Look

Helium Conservation Strategies
Ever since the space shuttle program was cancelled, NASA and the Kennedy Space Center have been rebranding themselves. While they will continue to build and launch spacecraft for exploration and other government projects, the earlier single-minded focus on the shuttle program has broadened. NASA has now taken its sprawling complex and is essentially leasing space and capabilities to tenants. While those tenants consist mostly of subsets of NASA working in different areas of aerospace, two are private companies-SpaceX and United Launch Alliance-and there are likely to be more in the future.

"It used to be that the only customer we had was the shuttle program," says Dan Tierney, sustaining systems engineer for URS Corporation, a contractor working with NASA at the Kennedy Space Center. "Since they were the sole user of everything that was supplied, there was no need to monitor usage. Now that the shuttle program has ended and NASA has various customers, we need to bill each one separately for everything we supply them. For liquids and gasses that meant that we had to install metering.

"For a variety of reasons, the two most difficult flows to measure are nitrogen and helium gas," says Tierney. "Both are vital in rocket and spacecraft use. Nitrogen is a propellant and helium has three uses. It is used to remove atmospheric moisture from cleanroom facilities. Because helium is an extremely small molecule and can find its way through the tiniest opening, it is valuable as a leak detector on spacecraft. Third, it is used in high volumes in launch support. Since helium will not freeze upon expansion, as most gasses will, it is used as a purge gas to sweep out combustible vapors from rocket engines and engine compartments. We call it 'safing'."

Enhanced metering was seen as a way to optimize helium use. Helium [is] very expensive-10 times the cost of nitrogen, so conservation is key.

URS performed a major search for meters that could not only measure gas, but also gas at low flow rates. "While many of the meters provided acceptable accuracies, operating and maintenance costs played a big factor," says Tierney. "All but one of the meter types was intrusive and had to be exposed directly to the flow." That meant an expensive installation, as well as costly maintenance. Because the meters were exposed directly to the flow, they would experience wear. "That meant that down the road, we would have to shut down, remove the meter, clean or replace parts, and start up again," says Tierney. "That added greatly to the long-term cost."
The chosen meter in this case was a clamp-on ultrasonic meter by FLEXIM, which didn't have to be exposed to the fluid flow stream and showed a high accuracy at all flowrates.

Transit-Time Ultrasonic Flowmeters Applied
"The technique most ultrasonic flowmeters use is called transit-time difference. Transit-time ultrasonic flowmeters exploit the fact that the transmission speed of an ultrasonic signal depends on the flow velocity of the carrier medium, kind of like a swimmer swimming against the current," says Peter Chirivas, an engineer at FLEXIM Americas, the maker of the meter selected. "The signal moves slower against the flow than with it."

When taking a measurement, the meter sends ultrasonic pulses through the medium, one in the flow direction and one against it. The transducers alternate as emitters and receivers. The transit time of the signal going with the flow is shorter than the one going against. The meter measures transit-time difference and determines the average flow velocity of the medium. Since ultrasonic signals propagate in solids, the meter can be mounted directly on the pipe and measure flow non-invasively, eliminating any need to cut the pipe. We also adapted the technology to measure flows as slow as that of groundwater.

The ultrasonic flowmeter clamps directly onto pipes, providing flow measurement and leak
detection. (Photo courtesy of FLEXIM AMERICAS Corp.)

Semiconductor
Two East Coast semiconductor manufacturers also opted for ultrasonic metering, but for different applications.
"We use helium in the chip making process," says Anne, a professional engineer at a major Mid-Atlantic chipmaker. "We use it as a shield gas in clean rooms to keep pollutants off the wafers and as a push gas because it is inert.

"With the cost of helium going up for the foreseeable future, we knew we had some leaks in the system," says Anne. "We compared our tool data to our flowmeters and we had a mismatch. We were missing some gas and we weren't sure where it was going. We needed a way to detect the leaks so they could be sealed. Helium can get through the tiniest opening."

The first time Anne heard of ultrasonic metering as a leak detector was at the Chem Show at the Jacob Javits Center in New York City. "There aren't that many clamp-on flowmeters that will read gas accurately at a low level," says Anne. "We had looked at ultrasonics before and we did buy a unit some time ago, but it didn't have leak-detection capability and it was permanently installed elsewhere.

"We needed something we could use on the distribution network that led to the chip-making tools," says Anne. "If we put flowmeters on every line it would cost a small fortune, not to mention the production loss from the downtime it would take to install the meters."

The FLEXIM meter we chose was portable and worked on all of the pipe sizes. It also measured slow flows very accurately. "We've been going to each lateral and totalizing the flow over a particular period of time," says Anne. "Then we compared that to the tool's mass flowmeters. When we first rented the FLEXIM meter, we compared its performance to our building flowmeters. And the FLEXIM meter was quite accurate."

After going lateral by lateral and comparing the ultrasonic flowmeter's results to the tools' mass flowmeters, the manufacturer identified a leak in one of the tools fairly early in the process. "We put the FLEXIM on and the background levels stayed too high for the flow," says Anne. "We got a window to shut down each tool and went one-by-one until we found it. So we were able to find and repair a leak with little-or-no loss of production."

Jack Sine is a freelance writer specializing in petrochemical, HVAC, flow technology, and environmental issues. He can be reached at jack.sine@verizon.net or 845 831-6578.

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CASE STUDY: Using Clamp-on Ultrasonic Flowmeters for Accurate Helium Measurement - Flow Control Network

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The portable ultrasonic flowmter accurately measures flow at even the slowest rates. (Photo courtesy of FLEXIM AMERICAS Corp.) Since 1996 the demand for helium has been ramping up, as supply remains fairly static. Accordingly, prices have risen sharply. For example, in 2014 the price for crude helium is estimated to increase 30 percent.