In a variety of oil production and refining environments, FCI’s ST100 Series mass flow meters monitor total gas flow to flare stacks as well as through feed lines to the main flare header. As an integral part of energy conservation and emission control systems, it meets strict accuracy and wide turndown requirements. The ST100 is highly reliable because of its durable construction and no moving parts design. Units are also used to assist in the control of steam addition and blower and louver adjustment for smokeless flares. A packing gland option permits hot-tap installation and retraction of the flow element without system shut down. The ST100 also features high flow range turndown ratios up to 1000:1 and micro-processor based userfriendly electronics.

ST100 Series mass flow meters provide the solutions for several difficult tanker loading/unloading applications. It is used to measure the flow of hydrocarbon vapors that are vented from the storage tanks, both on the tanker and at the port tank farm, to ensure compliance with environmental laws governing waste vapors. It is also used to measure nitrogen gas flow to inerting and gas blanketing systems that are often required in these operations. Finally, FCI’s ST100 may be used to measure flows to flare systems to assist in determining “through put loss” for the tank farm.

In monitoring chemical and other additive injection flow, the ultrasensitive FLT93L inline FlexSwitch® outperforms the competition. It detects gas flows down to 0.6 cc/sec and liquid flows down to 0.02 cc/sec -- ideal for virtually all injection processes. The nomoving- parts flow element design provides outstanding durability and reliability under the harshest process conditions. And, the inherent thermal time delay, available in all FCI flow switch/monitors, prevents false alarms caused by flow pulsation and eliminates the need for auxiliary time delay relays. Optional dual switch point circuitry helps maintain product quality and process safety by alarming both high flow and low flow conditions.

FCI FLT93S FlexSwitch Series have continued to play a key role in the automation of oil well testing facilities throughout the United States. Thousands of units are in service today, monitoring the flow of crude oil from the well, so that non-producing sites can be quickly identified and corrected. In addition to improving productivity, this efficient no-flow detection system eliminates time wasted on the continued testing of non-producing wells. These rugged FlexSwitch monitors enable the system to automatically switch to the next well in the test cycle.

FCI’s FLT93S FlexSwitch Series is well suited to monitor production in oil wells and indicate when an extended pump-off condition occurs. Coupled with a programmable logic controller, the FLT93S can control the operation of the well to optimize oil production; while minimizing wear and tear on the down hole pump. In addition, restricting the operation of the pump to periods when oil is produced saves energy and reduces operating costs.

Nitrogen is utilized for purging and blanketing throughout a chemical plant /refinery. The possibility of contaminating the nitrogen supply with hydrocarbon gas exists if the pressure at the destination becomes greater than the pressure at the source. The FCI RF83 bi-directional flow monitor is used to shut down the supply line if flow is detected returning back to the supply tank.

Unlike density-dependent displacers, often used for level and interface control, the FLT93S FlexSwitch Series relies on the specific heat transfer properties of the media involved to identify product interface. Because of this unique detection feature, interfaces between products of similar density are reliably controlled in separating tanks and other vessels. FCI liquid level and interface controllers can identify the interface between any media including liquids, slurries, foams and even emulsion layers. The dual switch point option allows one instrument to control two different product interfaces. Two or more units are used to control product discharge and intake at specified points.

The measurement and control of mill air flow in coal-fired boilers to minimize pulverizer performance problems is an industry-wide challenge. Minimizing Nox and maximizing plant efficiency has now taken center stage for this task. Measurement of air flow is important in controlling mill slugging, feeder runback and coal spillage. It is also a main factor in minimizing emissions and maximizing fuel response to the furnace, thus maximizing efficiency for these plants. FCI’s MT Series multipoint mass flow meters measure wide flow rate ranges in high temperature applications. The no moving parts design prevents highly corrosive fly ash from clogging or fouling.

Changes in the discharge flow represents air in-leakage through the compressor. The negative effects of air in-leakage in the vacuum system are well understood. FCI's GF90 Series mass flow meter detects small changes in flow that represent changes in efficiency of the compressor. Pre-requirements for successful monitoring require low flow sensitivity, wide flow range measurement, repeatability and accuracy -- all of which are standard features of FCI thermal mass flow meters.

Hydrogen is a commonly used cooling agent in power plant turbine generators. Leaking hydrogen gas can pose a safety concern in the power plant. FCI’s GF90 Series mass flow meters detect increase in usage; thereby alerting operators of leaks. In addition to monitoring for hydrogen leaks, plants need to measure the flow rate for custody transfer billing verification from the gas supplier to the utility. Also, multiple plants typically draw from a common hydrogen supply by using FCI’s GF92 inline unit. FCI’s GF Series mass flow meters measure the flow at each location, so each plant can be assessed their appropriate share of hydrogen usage.

To ensure critical flows and detect changes in the direction of air purge in and out of chemical plants, the solid-state RF83 bi-directional flow monitor is the best suited instrument available. It may be mounted on the inlet ducts to monitor all flow into the building. If the flow reverses, safety alarms will trip for failure notification of the fans.

FCI’s FLT93S FlexSwitch® is the ideal instrument to protect pumps from failure due to low flow operation. The no moving parts design, capable of low flow sensing, is well suited to identify a wide variety of product flows in harsh industrial environments. The dual switch points may be set to alarm low flow or high temperature, both indications of conditions that cause pump failure.

Frequently, in a plant environment, there is a controller that monitors the use of compressed air within the facility. The controller automatically determines the optimum number of compressor units that need to be in operation at any given time to handle the facility load. By only operating the units that the demand requires, a tremendous amount of energy is saved. The demand is determined by the total mass flow of air used by the plant, and FCI’s ST98 FlexMASSter® Series mass flow meters are designed specifically for this purpose. The controller then sets the compressor usage based on the mass flow rate indicated by the ST98.

Coolant and lubricant seal leakage are a serious threat to the efficiency of pumping systems. Fluid contamination to the product and loss of product through damaged seals are avoided with FCI’s FLT93L inline FlexSwitch or FR78 inline low flow monitor. Even a leak as small as 1.0 cc/sec is detected by these highly sensitive instruments. Because the FCI sensor elements operate without obstructing the seal vent line, there is no excessive pressure drop if a severe seal rupture occurs. For slurry pumps, the dual switch point option may be used to identify either a low seal water flow or a high flow seal rupture.

Food processors require proper air flow to ensure optimum growth and high quality of many products, for example -- yeast, cheeses, etc. A reliable and accurate flow meter for this application is FCI’s ST98 FlexMASSter® Series. The ST98 is installed on the air inlet line to the batching vessel to monitor inlet air flow and temperature. The 4-20mA output may be used to input the plant distributed control system or programmable controller.

Measuring hydrogen flow to a hydrogenation reactor is crucial in the manufacture of pharmaceuticals. Reduced hydrogen consumption by the process is a critical indication of the completion of the batching process. The ST98L FlexMASSter Series, with its wide turndown, is ideal for measuring flow during both the high demand batching process and the low demand at the completion of the batch. A second critical factor in this process is reducing hydrogen leaks to safe limits. An integrated system of FCI’s inline mass flow meters is required to continuously measure the hydrogen flow. The ST98L provides accurate indications of uptakes of hydrogen in the reaction process. And coupled with a wide range totalizer, our system will serve as a much needed safety interlock by initiating a shutdown sequence to manage hydrogen bleed-off.

Measuring hydrogen flow to a hydrogenation reactor is crucial in the manufacture of pharmaceuticals. Reduced hydrogen consumption by the process is a critical indication of the completion of the batching process. The ST98L FlexMASSter Series, with its wide turndown, is ideal for measuring flow during both the high demand batching process and the low demand at the completion of the batch. A second critical factor in this process is reducing hydrogen leaks to safe limits. An integrated system of FCI’s inline mass flow meters is required to continuously measure the hydrogen flow. The ST98L provides accurate indications of uptakes of hydrogen in the reaction process. And coupled with a wide range totalizer, our system will serve as a much needed safety interlock by initiating a shutdown sequence to manage hydrogen bleed-off.

FCI has been a major supplier of flow switch/monitors for HVAC systems since 1978. Selected for its reliability and sensitivity, the FLT93F is available to meet standard industrial and commercial HVAC requirements. Models can be supplied for detecting at rates as low as 0.25ft/sec -- compared with differential pressure and mechanical flow detectors that become insensitive below 30ft/sec. By directly sensing flow, the FLT93F FlexSwitch Series is able to detect filter blockage, blocked ducts and other failures not detected by blower current monitoring detectors.

Frequently, in a plant environment, there is a controller that monitors the use of compressed air within the facility. The controller automatically determines the optimum number of compressor units that need to be in operation at any given time to handle the facility load. By only operating the units that the demand requires, a tremendous amount of energy is saved. The demand is determined by the total mass flow of air used by the plant, and FCI’s ST98 FlexMASSter Series is designed specifically for this purpose. The controller then sets the compressor usage based on the mass flow rate indicated by the ST98.

Carbon dioxide is used in the bottling process to displace air from containers during filling and capping. Velocity flow meters are not suitable for this application because they are not able to accurately measure the widely varying mass flow rates encountered in start-up and low production periods. FCI’s ST98 FlexMASSter Series has the low flow sensitivity required for these start-up and low flow rates, as well as wide turndown capability to handle normal production rates for accurate accounting and quality control.

In the bottling business, there are many critical applications that depend on reliable indication of liquid flow. These include preventing carbon dioxide addition, stopping the bottling line, or shutting down chillers or refrigerant systems upon loss of product flow. FCI's FLT93C Sanitary FlexSwitch and FS2000L NuTec® inline flow switches are specifically designed to provide the highest level of dependability and cleanliness in these critical applications.

Rotating equipment, such as pumps, typically use a seal system to prevent process fluids from leaking into the atmosphere. These seals are charged with either an inert gas or a liquid similar to glycol. FCI's FLT93L FlexSwitch® inline flow switch is typically installed in the line feeding fluid to the pump to detect the extremely low flow volumes consumed by a normal operating seal. When a seal deteriorates, the leakage flow volume increases and is detected by the switch immediately activating a set point alarm for the operator to schedule an overhaul of the seal before actual contamination of process fluid appears. FCI offers various styles of inline flow switches capable of detecting flows as low as 0.05 cc/min in liquids and 1 cc/min in gases.

Pumping systems are extremely important to the safety and economical operation of chemical plants. Demand is very high for plant systems to be 100% operational with minimal downtime. As a result, flow monitoring for reliable and trouble-free pump protection is a necessary requirement. FCI's FLT93S FlexSwitch detects extremely low flow rates which can prevent the potential for pumprun- dry events. Preventative flow monitoring extends the pump lifecycle and increases the intervals between scheduled maintenance. The FLT93S FlexSwitch flow sensing element features no moving parts with all welded material of construction in virtually any kind of exotic metal. The flow switch features two adjustable alarms that can be set at low flow and no flow (indicating an empty pipe). Temperature compensation is a standard product feature that allows the alarm set points to be set for seasonal operating temperature ranges or start-up conditions. The FLT93S FlexSwitch is optimally installed in the feed line or discharge line of the pump.

Many chemical processes require large varying volumes of nitrogen, argon and oxygen for inert ion or purging, hydrogen as a catalyst, and many other gases. FCI's GF90 Series mass flow meters measure mass flow directly for process control and/or inventory purposes. FCI flow meters measure very low gas flows for leakage monitoring and are installed with no pressure drop in the process media. The GF90 Series features wide flow range turndown ratios up to 800:1 and integral or remote electronic configurations with HART, Profibus or Modbus in accordance with FM and ATEX approval standards. NIST traceable calibration certificates are supplied with every flow meter as a standard product feature.

The reactor is often the central process of every chemical plant. FCI's FLT93 FlexSwitch Series is used for various applications to protect and insure the accuracy of reactor processes. FCI flow and level switch products feature rugged design with a high level of reliability. For low level monitoring, the FLT93S is mounted in the reactor or the reactor discharge line to detect an empty reactor thereby eliminating contamination between batches. The FLT93S is also used for high level monitoring and to detect the interface of foam or emulsion. Inside the reactor vessel, FCI multipoint level assemblies are used to detect interface levels and indicate non-miscible fluid volumes.

A variety of industrial chemical environments use the FCI GF90 Series mass flow meters to measure total gas flow to flare stacks and in feed lines to the main flare headers. The GF90 Series features a no moving parts design, high reliability with durable construction and extremely low flow range detection as mandated by EPA regulations. FCI mass flow meters are also used to balance and optimize the control of steam addition, and blower/louver adjustment for smokeless flares. An optional retractable packing gland assembly permits hot tap installation and retraction of the flow element without system shutdown. Microprocessor-based electronics and a built-in keypad provide user-friendly operation and maintenance, high performance, and easy on-site programming.

When installed in lateral lines or downstream of relief valves feeding into the main flare header, the FCI FLT93 FlexSwitch Series can quickly and precisely indicate the source of flare gas thereby allowing the plant operator to readily identify problems in the process. As a relief valve monitor in flare systems or other processes, one FLT93S FlexSwitch can be calibrated to detect product "blowdown" and leakage using the standard product features for sensing wide flow ranges and two set point alarms.

In many plant operations, nitrogen is used to control the process media or avoid unwanted contact of the process media with oxygen /air. Reactors are filled and /or blanketed during operation with nitrogen. Continuous flow monitoring of nitrogen feed lines can prevent: excessive gas consumption, hazardous situations due to insufficient gas supply, and expensive gas leakages. FCI's FLT93 FlexSwitch flow switches and ST98 FlexMASSter® Series flow meters are used for these applications and feature a wide flow range (turndown ratio), direct mass flow measurement, and no pressure drop in the process media.

The difficult and challenging interface application of black liquor and soap is solved by using FCI’s thermal dispersion technology to differentiate between the black liquor and soap at the high and low levels in the skim tank. FCI’s FLT93S FlexSwitch® level switches feature a rugged, no moving parts design with 316L all welded stainless steel that is not prone to the typical failure of mechanical flotation devices or dp level systems. The FLT93S FlexSwitch also feature two field adjustable alarm relays and is temperature compensated for wide temperature changes in process media.

The amount of chemical recovery that takes place in pulp and paper mills has a direct impact on profitability. Lime is an important chemical used in the mill cooking process and the lime kiln consumes tremendous amounts of fuel that can be very costly to its recovery. FCI’s ST98 FlexMASSter® Series mass flow meters provide exceptional accuracy in measuring mass flow to insure proper natural gas/air ratio for maximum efficiency. The ST98 FlexMASSter features thermal dispersion technology with no moving parts and all welded 316L stainless steel construction. This technology also features mass measurement of very low flow rates with wide turndown capabilities and no pressure drop in the process media.

The start up cycle of recovery boilers is a very critical application that commonly uses atomized #2 fuel oil and steam. Inconsistencies in fuel oil flow leads to a longer start up process that directly impacts profitability. FCI’s FLT93L FlexSwitch inline flow switches feature no moving parts with 316L all welded stainless steel construction that provide outstanding reliability and extreme low flow sensitivity. The FLT93L FlexSwitch also features two alarm relay circuits that can be field adjusted or factory preset for low and high flow alarm conditions, offering additional safety during process operation.

Mill power plants maximize efficiency and reduce NOx emissions by accurately measuring the ratio of pulverized coal to air in coal-fired boilers. Air flow measurement and accuracy is also important in controlling mill slugging, feeder runback and coal spillage. FCI’s MT Series multipoint mass flow meters accurately and reliably measure wide flow ranges in these high temperature, erosive applications. The MT Series features flow elements with no moving parts design and stainless steel or optional Hastelloy C materials of construction that will not plug or foul when exposed to very high temperatures.

FCI’s FLT93S FlexSwitch flow switch is the ideal instrument to protect pumps from failure due to low flow or loss of flow. With no moving parts design, high reliability and extreme low flow sensitivity, the FLT93S FlexSwitch is ideally suited to monitor a wide variety of processes in harsh industrial environments. The FLT93S dual switch point circuitry is field adjustable to alarm on low flow or high temperature, both contributing factors of pump failure.

In monitoring chemical and other additive injection flow, the ultrasensitive FLT93L inline FlexSwitch outperforms the competition. It detects gas flows down to 0.6 cc/sec and liquid flows down to 0.02 cc/sec -- ideal for virtually all injection processes. The nomoving- parts flow element design provides outstanding durability and reliability under the harshest process conditions. And, the inherent thermal time delay, available in all FCI flow switch /monitors, prevents false alarms caused by flow pulsation and eliminates the need for auxiliary time delay relays. Optional dual switch point circuitry helps maintain product quality and process safety by alarming both high flow and low flow conditions.

Frequently, in a plant environment, there is a controller that monitors the use of compressed air within the facility. The controller automatically determines the optimum number of compressor units that need to be in operation at any given time to handle the facility load. By only operating the units that the demand requires, a tremendous amount of energy is saved. The demand is determined by the total mass flow of air used by the plant, and FCI’s ST98 FlexMASSter Series mass flow meters are designed specifically for this purpose. The controller then sets the compressor usage based on the mass flow rate indicated by the ST98.

The flow measurement of digester gas is critical to waste water treatment plant operations. Typical plants have multiple digesters that need constant monitoring. FCI’s ST98 FlexMASSter® Series mass flow meter provides extremely low flow sensitivity and wide turndown range. The no moving parts design is unaffected by this dirty, humid gas.

Many sludge clarifiers separate solids from the effluent system by introducing air and flocculants, so that sludge rises to the top the vessel and spills over a weir. The amount of air and flocculant are controlled by the level of the interface between the sludge and water. Optical detectors, as interface sensors, have not been successful in this application because the sensors fail due to fouling. FCI’s FLT93S FlexSwitch® Series multipoint assembly identifies the changing level of the sludge interface to enable control of flocculant and air addition.

Advanced water treatment plants are using ozone and activated carbon filters to reduce chlorine requirements in order to improve the taste and appearance of the water they produce. On-site generation of ozone can become a significant operating expense; thereby making its measurement and control an important requirement to efficient operation of the plant. Ozone flow needs to be introduced into the filtration process at three different points: For coagulation prior to primary filtration, for low flow as an oxidizing agent, and for high flow disinfecting to breakdown pesticides. FCI’s ST98L FlexMASSter inline mass flow meters are installed at each point to measure the ozone flow. The ST98L has the dynamic flow range and accurate sensitivity required for ozone applications.

Municipal water districts and waste water treatment facilities use chlorine to disinfect water. Proper, real-time control of chlorine dosage is critical to ensure smooth operation. FCI’s ST98 FlexMASSter Series mass flow meters with a Hastelloy C-276 flow element installed directly in the chlorine line ensures this critical flow. It is specifically calibrated to anticipate chlorine demand based on water temperature, flow rates, time of year and residual chlorine levels.

Large water storage reservoirs are often filled and drained through the same water line. Federal and state requirements mandate that all water delivered for human consumption be disinfected. In order to minimize disinfectant usage, avoid overdosing and forgo disinfecting water going into the reservoir, it is critical for water plant operators to know the direction of water flows within the pipe lines. The use of FCI’s RF83 bi-directional flow monitor detects instantaneous flow direction, providing improved disinfectant control.

In monitoring chemical and other additive injection flow, the ultrasensitive FLT93L inline FlexSwitch outperforms the competition. It detects gas flows down to 0.6 cc/sec and liquid flows down to 0.02 cc/sec -- ideal for virtually all injection processes. The no-movingparts flow element design provides outstanding durability and reliability under the harshest process conditions. And, the inherent thermal time-delay, available in all FCI flow switch /monitors, prevents false alarms caused by flow pulsation and eliminates the need for auxiliary time-delay relays. Optional dual switch point circuitry helps maintain product quality and process safety by alarming both high flow and low flow conditions.

FCI inline flow switch /monitors are an integral part of sampling equipment ranging from ultra-sensitive gas chromatographs to large fluid sampling systems used to test for toxic agents in wastewater effluent. Highly repeatable, with low flow sensitivity, FCI flow switches ensure that sample rates will be maintained at the right flow for accurate analysis. In systems where several products are tested individually by the same analyzer, each sample line is monitored to verify that products are flowing one at a time. The FR73 inline ultra low flow monitor is especially well suited for gas chromatographs; while the FLT93S FlexSwitch Series and FR78 inline low flow monitor are recommended for larger analyzers.