Fc i Pulp Paper Guide

User Appl i cat ion Guide

The mass flow experts for flow, level

and temperature instrumentation

Pulp and Paper Industry

YEARSOF

SERVICE

40

rom the early 1960s, Fluid Components Internationalrecognized the need for flow and level instrumentationwhich met specific customer requirements and

demands for the Pulp and Paper Industry. By utilizingThermal Dispersion and Coriolis Technology exclusively in allFCI flow, level, interface, temperature switches and mass flowmeters, our products solve typical Pulp and Paper Industryapplication challenges with standard product features such as: No moving parts All welded materials of construction Direct mass flow measurement No pressure drop Explosion-proof design Wide flow range Low flow capability

By closely monitoring the everchanging requirements for the Pulpand Paper Industry, FCI has maintained its reputation as the numberone technology leader with new product features such as: Modern digital communications with HART, Modbus,

Profibus, Ethernet and ASI Fail-safe mode selection per Namur NE43 Compliance with the latest approval requirements

of FM, CSA, CRN, ATEX, CE Mark and PED Application focused marketing and engineering research

and design Secondary sealed flow element sensor design Integral flow conditioners Two-wire intrinsically-safe flow, level and

interface detection

FCI Pulp and Paper Industry customers International Paper Georgia-Pacific Kimberley-Clark Proctor and Gamble Smurfit-Stone Weyerhaeuser MeadWestvaco Appleton Papers Bowater Tenbec Abitibi-Consolidated Alabama River Pulp Mobile Paperboard Boise Cascade

FCI Pulp and Paper Industry customers forEngineering, Procurement & Construction (EPC) B.E. & K. Kvaerner PLC Group Jacobs Engineering Kellogg Brown & Root R.M. Parsons J.A. Jones The Boldt Company Fru-Con Construction Fluor Corporation H.B. Zachry Sandwell Engineering

Solv ing cr i t i ca l process appl i cat ions for the Pulp and Paper Industry

Interface Detection

The difficult and challenging interface application of black liquorand soap is solved by using FCI’s thermal dispersion technology todifferentiate between the black liquor and soap at the high and lowlevels in the skim tank. FCI’s FLT93S FlexSwitch® level switches featurea rugged, no moving parts design with 316L all welded stainlesssteel that is not prone to the typical failure of mechanical flotationdevices or dp level systems. The FLT93S FlexSwitch also feature twofield adjustable alarm relays and is temperature compensated forwide temperature changes in process media.

Natural gas flow monitoring

The amount of chemical recovery that takes place in pulp and papermills has a direct impact on profitability. Lime is an important chemicalused in the mill cooking process and the lime kiln consumestremendous amounts of fuel that can be very costly to its recovery.FCI’s ST98 FlexMASSter® Series mass flow meters provide excep-tional accuracy in measuring mass flow to insure proper naturalgas/air ratio for maximum efficiency. The ST98 FlexMASSter featuresthermal dispersion technology with no moving parts and all welded316L stainless steel construction. This technology also features massmeasurement of very low flow rates with wide turndown capabilitiesand no pressure drop in the process media.

Fuel oil monitoring

The start up cycle of recovery boilers is a very critical applicationthat commonly uses atomized #2 fuel oil and steam. Inconsistenciesin fuel oil flow leads to a longer start up process that directlyimpacts profitability. FCI’s FLT93L FlexSwitch inline flow switchesfeature no moving parts with 316L all welded stainless steel con-struction that provide outstanding reliability and extreme low flowsensitivity. The FLT93L FlexSwitch also features two alarm relaycircuits that can be field adjusted or factory preset for low and high flowalarm conditions, offering additional safety during process operation.

Combustion air flow monitoring

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

Pump protection

FCI’s FLT93S FlexSwitch flow switch is the ideal instrument to protectpumps from failure due to low flow or loss of flow. With no movingparts design, high reliability and extreme low flow sensitivity, theFLT93S FlexSwitch is ideally suited to monitor a wide variety ofprocesses in harsh industrial environments. The FLT93S dual switchpoint circuitry is field adjustable to alarm on low flow or high tem-perature, both contributing factors of pump failure.

Chemical injection

In monitoring chemical and other additive injection flow, the ultra-sensitive FLT93L inline FlexSwitch outperforms the competition. Itdetects gas flows down to 0.6 cc/sec and liquid flows down to0.02 cc/sec -- ideal for virtually all injection processes. The no-moving-parts flow element design provides outstanding durabilityand reliability under the harshest process conditions. And, the inherentthermal time delay, available in all FCI flow switch /monitors, preventsfalse alarms caused by flow pulsation and eliminates the need forauxiliary time delay relays. Optional dual switch point circuitry helpsmaintain product quality and process safety by alarming both highflow and low flow conditions.

Compressed air flow monitoring

Frequently, in a plant environment, there is a controller that monitorsthe use of compressed air within the facility. The controller auto-matically determines the optimum number of compressor units thatneed to be in operation at any given time to handle the facility load. Byonly operating the units that the demand requires, a tremendousamount of energy is saved. The demand is determined by the totalmass flow of air used by the plant, and FCI’s ST98 FlexMASSterSeries mass flow meters are designed specifically for this purpose.The controller then sets the compressor usage based on the massflow rate indicated by the ST98.

CI introduced the first thermalflow switch /monitor in 1964and has since established a

worldwide reputation for the design andproduction of precision high performanceflow, level and temperature instrumentation.With reliability second to none, FCI hasplaced over 200,000 units in the fieldcovering the full range of liquid, gas andslurry process requirements. FCI productsservice some of the world's most demandingprocesses in industries such as food &beverage, pharmaceutical, chemical, oiland gas, pulp and paper, power and energy,water and wastewater, nuclear power,aerospace and more. FCI offers a broadrange of instrumentation solutions andservices, from off-the-shelf devices to customengineered systems. FCI's engineeringstaff provides expertise in mechanical,electronic and thermo-dynamic disciplinesoffering innovative solutions to specializedcustomer application needs, configurationobjectives, software enhancements, andmaterial problems.

Thermal Dispersion PrincipleThe typical sensing element contains twothermowell-protected precision platinumResistance Temperature Detectors (RTDs).When placed in the process stream, oneRTD is heated and the other RTD senses theprocess temperature. The temperaturedifference between the two RTDs is relatedto the process flow rate as well as the

properties of the process media. Higherflow rates or denser media cause increasedcooling of the heated RTD and a reductionin the RTD temperature difference.

FlexSwitch® FLT93 SeriesThe FLT93 Series utilizes proprietary thermaldispersion technology to provide the highestreliability in flow, level and temperaturedetection. The sensing element is composedof two matched RTD's. One RTD is prefer-entially heated. The other RTD is unheatedand thermally isolated to provide continuousprocess condition temperature and baselineindication. At no flow or under dry condi-tions, the temperature differential betweenthetwo RTDs is greatest.

For flow / no flow detectionNo-flow condtions produce a large signal.As flow increases, the heated RTD iscooled and proportionally reduces thetemperature differential. Changes in flowvelocity directly affect this rate of heatdissipation. An electronic circuit normalizesthe differential measurement with theprocess media temperature and converts

the RTD temperature/resistance differentialinto a DC voltage signal. This signal isprovided at output terminals and used todrive two adjustable setpoint alarm circuitsthat are independently field configurablefor specific flow service applications.

For liguid level /interface detection Dry conditions (no liquids present) producethe greatest temperature differential. Thesignal decreases when the level element issubmerged as the cooling effects of thefluid drive the temperature /resistancedifferential downward. Since all processfluids have different thermo physicalproperties, different fluids exhibit uniqueheat transfer characteristics. Interfacedetection between non-miscible fluids canbe factory or field calibrated to alarmwhen the fluid changes from liquid tofoam, between two different fluids, orbetween fluid and rag layer or emulsion.

continued on back cover

Product development, testing and calibration are performed in FCI’s laboratory using NIST traceableequipment, which ensures highly reliable performance in hundreds of applications.

Thermal mass flow technology supports virtuallyall gas or air measurement needs. It is especiallywell suited for dirty gas because of its no-movingparts design with no orifices, bearings, or sealsto foul or fail.

HeatedSensor

UnheatedSensor

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Serv ing cr i t i ca l process instrumentat ion needs around the wor ld

FCI’s complete line of flow, level and temperature instrumentation

Doc. No. 07SA011397A

� For temperature detectionThe unheated RTD serves as the baselinefor establishing the differential temperatureand continuous monitoring of the processtemperature. Being thermally isolated, theunheated RTD provides accurate indicationand detection of process fluid temperatures.Simultaneous temperature and flow andlevel detection can provide comprehensiveprocess monitoring as well as criticallysupplement operator process health andefficiency awareness.

NuTec® 2000 Series� 2-wire, intrinsically-safeand non-intrusive switchesExtraordinarily responsive and accurate,the versatile NuTec Flow/ Level switch seriesoffers superior reliability in extreme processconditions. The FS2000 and LS2000 switchesfeature the only 2-wire thermal flow/noflow and level detection switches withintrinsically-safe design. These insertionswitches are designed with FCI's proventhermal mass flow sensor technology in arugged package that is easy to install andrequires minimal maintenance. TheFS2000L inline flow switch has an advancednon-intrusive sensor design constructed of316L stainless steel with up to a 10 Raelectropolish finish approved for 3Asanitary and high purity applications. TheFS2000L is available with inline sizes of 1/2inch, 1 inch and 2 inches for easy installationusing male NPT, butt-weld or sanitary flanges.

FlexMASSter® ST Seriesand GF Series Mass FlowmetersBecause the relationship between flow rateand cooling effect directly relates to massflow in gas applications, FCI Thermal MassFlowmeters provide a highly repeatable andaccurate measurement of gas or air massflow rates. The ST98 Series "smart"electronics, equipped with advancedmicro-processor-based circuitry, enable

customers to reconfigure the signal outputseasily, as well as, display or alarm in thefield by using either a built-in key pad ora handheld communicator. The GF Seriesoffers wide turndown rations up to 800:1with multiple gas calibrations with analogelectronic circuitry.

FlexMASSter Technology delivers perform-ance and value by offering the mostinnovative, accurate and cost effective gasmass flow measurement systems availablein the industrial flowmetering marketplacetoday. This highly reliable instrumentprovides the durability and speed requiredfor today's harsh process environmentsand delivers true direct mass flow meas-urement. FCI's FlexMASSter simplifies gasmass flow metering with a single processpenetration, eliminating costly temperatureor pressure transmitters and a flow com-puter required with other technologies.

CMF FlexCOR® SeriesThe CMF FlexCOR Series Coriolis flowmeterspushes development a giant leap forwardin Coriolis measurement technology.Unaffected by variations in pressure, tem-perature, density, electrical conductivity andviscosity, the FlexCOR series provides highlyaccurate mass flow measurement overwide flow ranges while utilizing its advancedtechnology to achieve unsurpassedoperational performance stressing safety,reliability and quality.

VORTAB® Flow ConditionersFCI ensures the field performance of itshighly accurate mass flowmeter productlines by offering VORTAB Flow Conditioners.VORTABs ensure accurate, repeatable gasflow measurement and are the efficientalternative to long lengths of straight pipingor ducting upstream of a flowmeter instal-lation location. VORTAB units reduce oreliminate pressure drop, swirl, jetting and

more, while requiring just six diameters ofpipe upstream from the flowmeter. Eachof the three available flow conditionerconfigurations consist of a short sectionof swirl reduction tabs combined withthree arrays of patented VORTAB profileconditioning tabs.

FCI’s extensive instrument testand calibration laboratoryFCI maintains an extensive, instrumenttest and calibration laboratory at its head-quarters in San Marcos, California.Utilizing the latest in advanced, computerizeddata acquisition systems and calibrationtest equipment, this facility permits com-prehensive product development, testing,and calibration. Any FCI product can becalibrated in accordance with customerspecifications. Laboratory standards aremaintained with NIST (National Instituteof Standards and Technology) traceableCavitating Venturis (CVs) and precisioncalibrated, pressure and temperaturecorrected turbine flowmeters. Combustibleand non-combustible gas calibration flowstands allow for the calibration of FCIproducts in a wide range of gases as gasmixtures in flow stand sizes as small as1/8 inch to 30 inches [3 to 760 mm] indiameter. A variety of flow profiles fromlaminar to turbulent conditions aregenerated to duplicate actual field condi-tions. Flow rates from 0 to 20,000+ SCFM[0 to 34,000 NCMH], velocities from 0 to800 SFPS [0-240 NMPS], pressures fromvacuum to 3000 psig [200 bar(g)], andtemperatures from -100° to 850°F [-70°to + 454°C].

FCI on-site instrumentcalibration and trainingIn-situ calibration is available from FCI'sField Service engineers where precise testand calibration is accomplished in actualmedia conditions.

©Copyright 2006 by Fluid Components International LLC. All rights reserved. Subject to change without notice.

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