Vitalii Prokopiv, Author at Flowmetrics

Biofuel Microbes Engineered to Win

Posted on August 18, 2016 by Vitalii Prokopiv

Biofuel production still has some obstacles before it begins powering our daily lives. The main issue is contamination from a variety of sources, and a little bit of biological engineering aims to reduce the need for filtering.

To make a batch of biofuel plant matter and specific bacteria and yeasts are mixed together, then held in favorable conditions so that the microbes can eat the starch molecules and excrete a substance we can burn. One hang up with this process is that a whole plethora of microbes are capable of digesting the raw plant matter, yet only a small portion of them create fuels for us to burn.

If fuel-making microbes can eat the food source, so can other bacteria or yeast. When other microbes start growing, they reduce the efficiency of the process.

Sterilization is nothing new to production facilities, but to reach the purity required for use, a large amount of energy will be required to sterilize a production-sized batch. Another option is to add antibiotics to control the unintended additions. Unfortunately the remaining materials after fuel is extracted is exported to feed livestock and would increase the likelihood of drug resistant bacteria in the future. So in lieu of these methods a bit of engineering of the biological persuasion will give the proper microbes a fighting chance.

By manipulating the abilities of the bacteria and yeast into super-powered forms, scientists were able to get the microbes to digest non-natural materials for biofuels. In tests purposely contaminated with competing composting bacteria, the newly strengthened microbes were able to flourish naturally where other contaminating strains were severely hampered. The specifically engineered yeast and bacteria was able to out compete the other fauna, eventually starving them to extinction within the plant matter, leaving a purer form of biofuel.

Click here for the full article by Sam Lemonick.

A Guide to Ratemeters

Posted on August 17, 2016March 2, 2017 by Vitalii Prokopiv

Measuring flow requires that you have adequate means for reading information. Ratemeters and totalizers offer a user the ability to understand exactly what is happening within the mechanisms of flow metrics. Without these handy gadgets, measurement is far more difficult. It is important not to rush through this facet of flow measurement, as you might find that there are a number of variables to consider when choosing a ratemeter and totalizer. In the following, you will read about several different kinds of ratemeters.

The MINITROL

912-MRT The 912-MRT, otherwise known as the MINITROL, is a ratemeter with six digits and a two level, five digit preset alarm control. There are two inputs, A and B, which can be calibrated in three different ways:

“A” subtract “B”
“A” add “B”
“A” and “B” as separate totalizers

Moreover, the MINITROL can handle a whopping 10,000 pulses per second. With five digits and a floating decimal, you can measure in true blue engineering units with the rate set in terms of seconds, minutes or hours. You can also toggle between the current rate and total without disrupting the count. This ratemeter is perfect for all kinds of flow measuring fun.

918-RTP

918-RTP If you are searching for something a little more futuristic, you might want to look into the 918-RTP, which boasts a 2 X 16 backlit LCD display with a ratemeter and totalizer that you can preset by way of two pulse inputs. You can even connect this piece of equipment to a network for data acquisition. Like the MINITROL, the 918-RTP has two inputs (A and B), each of which can define up to 16 points of K-factors. What does this mean? Well, simply put, this allows for a greater degree of accuracy, which makes this ratemeter worthy of consideration for future purchase.

The KEPTROL

The 920-KRT8, known as the KEPTROL, is a serious meter allowing for 20,000 pulses per second. It is faced with a .55” screen that displays both numbers and letters. With a 16 point K-Factor this unit can give majorly accurate readings. Perhaps the most wondrous attribute of this ratemeter is its capacity to transmit data to remote totalizers, computers, programmable controllers and many other kinds of digital data storage devices. To top it all off, the KEPTROL offers you the ability to protect your information with a password. This can be useful if you are storing your equipment in a place that is accessible by other people or if the measurements belong to patented research that you want to keep away from the vying hands of competitors.

You might find that there are a lot of overlapping features, such as two programmable inputs, toggling capabilities, security features and alarms. Because of these shared features, it would be advisable to seek out an expert to help guide you through the tedious work of researching the many kinds of ratemeters. He or she can help you determine what you actually need. After all, an LCD screen might look sleek, but upon closer examination you might discover that it is actually superfluous.

Flow Control and Pressure Measurement

Posted on August 16, 2016 by Vitalii Prokopiv

Control operators rely on pressure readings to monitor the state of processes within the facility. Usually those employees responsible for recording the measurements read from Bourdon tube gauges and are manually entered into the data management system. Other than continual monitoring pressure readings can hint at upcoming maintenance.

Bourdon tubes gauges are a long standing tradition in pressure measurement, they are simple to install, operate, and low cost. Because of the little thought given to these gauges, they often are maltreated or neglected. Process fluids can be corrosive and pressure spikes can cause leaks or ruptures, leading to shortened lifespans for Bouron tubes. Fluid filled gauges can overcome some of the wear and tear from constant surges in pressure, but hearty taps from operators checking the gauges can cause more damage.

Upgrades do exist for Bourdon tubes, mainly in the form of wireless transmitting models, but this feature can cost up to 4 times as much per gauge. Ultimately the decision to use wireless models or traditional gauges depends on the design requirements of the system. Data from wireless gauges must be routed through a gateway connected physically to the data management system, and can only handle a specific maximum of devices through each gateway device.

Click here for the full article by Wally Baker.

PID Controls

Posted on August 15, 2016 by Vitalii Prokopiv

PID control stands for proportional, integral, and derivative control. This type of process management is used to maintain set parameters, and works well for temperature or motion. All three portions of this control setup manage whatever parameter you desire in different manners.

Proportional control controls how far the measured parameter is from the set parameter. In terms of temperature it will tell you how far off from ideal the process is running; i.e. +1.85 °F or -.07°F. Managing the process with proportional controls alone will work, but the systems will swing between over- and under- correcting.

Integral controls are added onto proportional controls to factor in timing into the setup. By measuring the time between measurements of the parameter the system can determine the speed at which the motion or temperature are changing; i.e. -.1 °F/second. By knowing this measurement the system can then account for this with more precision, cutting down the amount of over-correcting. Still this combination will need one final layer to appropriately maintain the parameter dynamically.

Derivative control measures the acceleration of the parameter, in effect the speed at which the speed is changing. With this level of control, the parameter changes can be dampened and returned to the set point reliably. In terms of motion parameters, with a properly installed PID control system a ball bearing can be kept from rolling off a glass plate even when pushed by people.

Click here for the full article and tuning tips by Mark Bacidore.

Water Corrosion Protection

Posted on August 12, 2016 by Vitalii Prokopiv

In steam producing boilers high temperatures and pressures increase the likelihood for corrosion and failure from said damage. The main culprit in this situation comes during the shutdown process, as pressure drops air enters the boiler and oxygen within the air reacts with the metal boiler causing weaknesses and pits in the metal. These small weaknesses can turn into leaks quickly requiring immediate shutdown.

To solve the problem of oxygen entering the system a nitrogen blanket can be installed. This is a system which fills the boiler system with nitrogen before dumping the pressure to eliminate air ingress, nitrogen is non-reactive in the system avoiding further pitting or corrosion. Supplying nitrogen for a blanket can come from bottled sources, liquid supplies, or through pressure swing adsorbtion.

Click here for the full article by Brad Buecker.

New Fuel Additives from Sugar

Posted on August 11, 2016January 10, 2019 by Vitalii Prokopiv

Mineral oil has been the chief raw material for fuel additives like isooctane, but new processes will produce gasoline additives from biological sources. For the first time additives to reduce premature ignition in engines will be produce from purely renewable resources.

These biobased additives will use a biobased isobutene as a starting material in a new process, sourced originally from sugar. Usually isooctane is produced from isobutene, but because the starting resource is biobased the new process will account for small differences in the properties of both chemicals. The production teams are intimately aware of the challenge of contamination from the raw materials and will approach the entire process with overall cost effectiveness in mind.

Click here for the full article by Fraunhofer-Gesellschaft.

Pump System Optimization

Posted on August 10, 2016 by Vitalii Prokopiv

As facilities seek lower energy usages, pump systems optimization ultimately comes up. The big drain to efficiency is that companies focus on the purchase price of a system rather than the life-cycle cost. On average the initial purchase of a system accounts for only 17% of the total costs, with 55% attributed to operation of the system. The inefficiencies of a system can lead to shortened life-span of pumps due to shaft wear and seal leaks. A pump should only run 15% outside of its best efficiency point at most to avoid these issues.

Proper assessment is required to discern the weaknesses in a pumping system before optimization can begin. Some items to look for in this assessment are;

Throttled flow-control valves
Recirculation flow regulation
On/off pump cycling
Pumping system without gauges to measure flow rate or pressure

Click here for the full article by Mark Sullivan.

Even After a Century, Rotameters Still Measure Up

Posted on August 9, 2016 by Vitalii Prokopiv

Numerous modern industries touching every aspect of day-to-day life utilize sophisticated liquid flow systems at some point during the manufacturing process. Rotameters, or variable area flow meters, are important tools used to measure the volume of flow for liquids. Though simple in design compared to other advanced metric equipment, rotameters are economical and accurate in measuring flow rates ranging from low to very high volume, and they are staples for quantifying production methods in many industries.

Simple Design That Delivers Precise Results

The first rotameter was invented in 1908, and though the original design has been improved, the basic operation is still the same after more than a century. A rotameter consists of a tapered tube, usually made of clear glass, with a float, which is actually a shaped weight, inside. When fluid flows through the tube, the weight is pushed up by the force of the liquid’s movement, thereby allowing quick and easy assessment of the overall flow volume.

There are distinct advantages to using these effective meters. Rotameters require no electricity or external fuel, and they can be produced in large quantities using relatively inexpensive materials. Their low manufacturing cost makes them available for widespread use, and the materials used to make them are resistant to shocks and chemical reactions.

They can be installed quickly and easily, and their accuracy is dependable. Furthermore, their measuring scale is approximately linear, making readings simple to understand and quantify.

Industries That Depend on Rotameters

Some vital industries that use rotameters include:

Energy
Aerospace and aviation
Food
Pharmaceutical
Chemical and petrochemical
Laboratory
General

Design Variations Improve Basic Operations

Modern design variations greatly expand the range of useful applications for rotameters. Their versatility, accuracy, dependability and cost-effectiveness make rotameters invaluable tools for measuring liquid flow rates in most facilities.

Some of the sophisticated modefications include:

Durable seals and shields
Heavy-gauge steel frames
Customizable measuring scales
Volume alarms

Why Rotameters Enjoy Enduring Popularity

The bottom line is that rotameters are simple yet accurate and dependable tools for measuring the liquid flow rate during many manufacturing and research processes. Today’s dynamic industries require efficient yet cost-effective ways to produce high-quality products according to strict schedules. Rotameters make it possible for them to do just that.

They are affordable and simple for any company to install, and they can withstand thermal shocks, temperature changes and chemical reactions alike and still deliver accurate readings. They are dependable and deliver repeatable results without drawing on any external power source.

Rotameters may seem simplistic in today’s fast-paced, increasingly complex technological world, but it is their elegant simplicity that makes these meters indispensable. From basic models that provide accurate measurements of flow volume to innovative designs that include alarms and custom scales, rotameters work well for most industries, as they have for more than 100 years.

While the design has been somewhat modified to meet modern production needs, rotameters still operate on the same basic principles that allow them to provide fast, accurate measurements. They help manufacturers ensure that daily processes are safe and efficient today and in the years to come.

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California Wind and Solar Power

Posted on August 8, 2016 by Vitalii Prokopiv

California is a natural gas powered state, but wind and solar are rapidly increasing in popularity. Hydroelectric power locations are dwindling, locations becoming more scarce and less efficient as more power plants are introduced. Even though these renewable power sources have increased in the total share of power supply to California, natural gas has increased its share as well, about 13% in just the last year. This phenomenon is due to the lack of reliability in wind and solar power generation, as these power plants cannot compete with the demand for power, natural gas plants are run to make up the difference.

Click here for the full article by Jude Clemente.

The Art of Calibrating

Posted on August 5, 2016August 5, 2016 by Vitalii Prokopiv

Basic calibrations of sensors combine a known environment tied to an output of that sensor. If a pressure sensor outputs a value of 2 psi when in a vacuum and 102 psi when placed inside a space with known pressure of 100 psi, the operator can calibrate the sensor to output 2 psi less than it currently does. Usually a sensors output is a linear affair between the stimuli and the reading it provides, and in these cases calibration is simple. By calibrating in this way the operator is introducing errors if they are off in any way.

If the testing situations are not accurately known any readings after calibration will have the same discrepancies. The use of a “golden unit” or a standardized unit of measurement to calibrate all sensors against can vastly reduce this type of error.

The calibration procedure should produce consistent results. If the operator can use the same procedure and calibrate the same sensor multiple times to the same end value then a sensor is much more likely to be accurate. If the sensor has varying levels of offset at the end each time, something must be fluctuating between calibrations.

Click here for the full article by Jim McCarty.