No matter the application, we probably already have a solution worked out
Why should you use a Thermal Instrument Mass Flow Meter?
- Rugged Construction – Stainless Steel with available protective coatings
- Measure Liquid & Gas Applications
- Unobstructed path for continuous flow and no pressure drop
- Wide Turndown for wide flow ranges
- Back up Sensors for extended life
- Sensors are protected and never come into contact with passing fluid
- Flow and Total Flow measured
- 4-20mA output to data recorders, PLC’s etc.
- Insertion probe available for simple installation and ease of cleaning
Landfill Gas & Leachate Measurement
Our flow meters are built to hold up to the harshest environments with standard 316SS and electrical housings that meet most certifications. The fact that our meters are rugged and that our sensors never come into contact with the passing fluid, unlike other flow meters, means that your one time investment will offer you many years of returns. In the event something does happen, all Thermal Instrument Mass Flow Meters come standard with redundant sensors. This feature alone, saves time and money by following a simple process of changing over to the spare sensor without ever removing the unit from your process line. Our in-line unit has a variety of process connections available and is typically only 6” in length. It is available in line sizes as small as ½” tube and piping up to 6” in diameter.
If space and process connections are limited then we also offer our insertion probe Model 62 which can provide the landfill operator with the same useful flow data that they need to effectively manage the landfill leachate. Like our inline Model 600, the sensors are still protected behind our standard 316SS construction in order to offer a long term flow measurement instrument resistant to corrosion, pressure, and temperature variations. The flow sensor can be constructed out of other materials, and can have a protective coating applied to provide another layer of defense. Our Model 62 insertion probe mass flow meter is our most versatile solution for measuring large line sizes as the length of the probe can be adjusted to suit the application needs. We have manufactured probes from 9” to 20’ in length.
What is leachate?
Leachate is the water that naturally drains down through the landfill levels collecting any dissolved or suspended materials as it passes through the ground. It is a naturally occurring event that must be accounted for, captured, and treated as it is a pollutant and the responsibility of the landfill operator to insure that this liquid makes it to a safe holding area prior to being treated.
That being said, traditional liquid flow meters that have moving parts are not a good solution for measuring the flow of leachate due to the high possibility that suspended particles may be flowing with the water clogging the instrument. Our mass flow meter Model 600 offers a completely unobstructed flow path eliminating pressure drop and a restriction point where those particles may clog. In addition, our in-line Model 600 can have a protective coating applied in the sensor area for extra protection and to insure water and the particles keep moving down stream.
Thermal Instrument Mass Flow Meters: Flexible Solutions, Durable Equipment, and Dependable Results.
MASS FLOW METERS FOR MEASURING LANDFILL GAS
Landfill Gas is a mixture of Methane, Carbon Dioxide, and Oxygen that is created by the decomposition of waste stored in landfills. According to the EPA, landfills are the third largest generator of Methane Gas. Methane Gas is the second most prevalent gas to contribute to the Greenhouse Gas (GHG) Effect and for that reason it is important to contain and process the Methane gas in a way that it does not increase the level of GHG’s in the Earth Atmosphere.
Landfill operators use a combination of wellheads, pumps, and piping to funnel these gases to a central point where they can either be burned off by a flare system or converted into renewable energy. Many Landfills now see this gas as a revenue source as they are able to contain it, send it to local power plants and create renewable energy. To that end, Landfill operators are responsible for collecting and accurately measuring the gas in order to benefit both the environment and offset their operating costs.
Our thermal mass flow meters are a key tool in measuring the amount of Landfill Gas being produced in order to comply with United States EPA Clean Air Act. We work with our customers to obtain the proper gas mixture and other operating conditions prior to calibration beginning. Our mass flow meter (Model # 62-9 pictured to right) is our most versatile solution and is calibrated to the exact gas mixture and operating temperatures that Landfill operators are working under. We perform the calibration in our factory flow stands so that our customers receive a unit that is ready to go right out of the box. The insertion probe comes standard with packing gland for easy installation, then connect your power source, and our standard 4-20 mA output for a start-up that takes just minutes. Our flow meters are installed and measuring gas flows to flares or to power plants, turning what was once waste into renewable energy.
RE-CALIBRATION OPTIONS TO MAINTAIN COMPLIANCE WITH EPA 40 CFR PART 98 REGULATION
When you need to service your thermal mass flow meter to remain compliant, we offer 3 solutions to our valued customers:
- Send the unit back for a full factory recalibration utilizing NIST traceable procedures and receive a certificate of calibration upon completion.
- Send the unit back to us and we can provide you with a loaner while we re-calibrate and certify original operating specifications. Just use the Landfill Recalibration link at top of page. Certificate of calibration is sent with the returned unit.
- OR contact us at 215-355-8400 and we can schedule on-site field service at your convenience. Our Service Engineer will work with you and your schedule to insure that you do not have any down time!
Landfill On-Site Calibration Process:
With our NIST traceable standard calibration equipment in hand, our service engineer is equipped to provide a proper documented “Calibration Certificate” to EPA Standards and a service report upon completion of his field site visit. Additionally, any type of deviations to the flow meter caused by installation errors or unpredicted application conditions will be re-tuned and adjusted on the flow meter while present. You as the customer can rest assured that the Thermal Instrument Company flow meter on your landfill vent is performing to an accuracy of +1% full scale and is just like new from the factory.
Mass Flow Meters Measuring #2 Fuel Oil & Other Hydrocarbon Fuels
Thermal Instrument Model # 600 In-line mass flow meter has been our primary instrument for measuring #2 fuel oils and other fuel oils as our technology allows for a high turndown ratio to capture wide flow ranges. In addition to the wide turn down, our unit offers a completely unobstructed flow path to eliminate any pressure drop, eliminating stress on motors and pumps. There are no intrusions to the flow path and all sensors are completely protected from the fluid insuring a long lasting, rugged instrument that will require minimal maintenance, keeping operational costs low.
Some applications of mass flow meters measuring #2 fuel oil are:
- Boilers and Furnaces using #2 Fuel Oil for heating systems
- Measuring diesel fuel to motors
- Fuel measurement to back up diesel generators at power stations
#2 Fuel oil is obtained during the petroleum distillation process, and is typically any liquid fuel that can be used in industrial boilers or furnaces to generate heat. During the refining process, others fuels are created such as jet fuel, gasoline, and diesel which are used to power an engine or to create energy.
Fuel Oil has several uses in industry and at times needs to be measured to insure production processes run efficiently. Since fuel oils are comprised of hydrocarbons, not all flow measurement instruments can accurately measure their flow in process applications. Hydrocarbons have no impact on the measuring capabilities of mass flow meters. That is why our thermal mass flow meter excels in these fuel oil measuring applications. There are many different types of fuel oil, but Thermal Instrument has had specific success in measuring #2 fuel oil and diesel fuel. Both #2 Fuel Oil and Diesel can be easily mistaken as both are dyed red in color, but they have unique applications. #2 fuel oil is typically used in boilers and furnaces to generate heat for either HVAC systems or industrial applications. Diesel fuel is primarily used to power engines or generators to create energy.
Our unobstructed, in-line mass flow meters are available in a wide range of sizes and can be easily plumbed into process lines as small as ¼” OD tubing and up to 4” piping and beyond with a variety of process connections available.
MASS FLOW METERS FOR COMPRESSED AIR SYSTEMS
Managing Leaks in Compressed Air Systems with Thermal Mass Flow Technology
Compressed air within a manufacturing facility has become quite high over the last decade, and so has the expense in operating them. Compressed air systems are found throughout industry and are often the largest end-use of electricity in a manufacturing plant. Compressed air leaks can be a significant source of wasted energy and should be addressed through the application of a thermal mass flow meter to monitor the out flow of compressed air to the upstream value.
The fact of the matter is, compressed air is not free and it’s becoming a financial burden to a company’s operating expenditures. It is now even more important as a means of reducing costs for companies to monitor their compressed air usage, identify the leak points within the air system, and replacing older equipment with newer items. Why is it so important to monitor the air flow rate in compressors? There have been extensive studies done over the years on plant wide operating costs for virtually any type of industry, and most facilities had 70 to 80% of their expenditures in electricity fees. The major contributor to this excessive electricity draw are the air compressors. The actions required though to reduce excess electricity usage and provide for a more efficient compressor throughput is to monitor the flow rate and optimize the compressor’s efficiency more.
Older compressor systems within facilities can operate very inefficiently, and through audits performed by air system compressor technicians, it is usually found that replacement of the compressor needs to happen. Some of these system management companies have stated that replacement of a new compressor system can provide a short term payback and results in monetary savings of up $35,000 per year with the elimination of air leaks.
After wide applicability on compressed air applications, thermal mass flow technology has distinct advantages that make it a much more effective technology versus other technologies. The technology lends itself to having a high turndown ratio and uses a single probe design for insertion into the customer’s piping arrangement. Accuracies down to + 0.5% of full scale and an even better on repeatability makes this technology shine over other measurement techniques. Now with the wide turndown ratio of 100:1 and even higher using thermal mass flow technology, the measurement range from very low velocities to higher flows can be measured with no problems. It is at the lower velocities where compressed air equipment begins to become weak and leakage starts to be seen here.
velocities requiring detection, the system cannot discern the flow velocities at the low flows. Additionally, orifice plate designs have to be compensated for changes in pressure and temperature in order to calculate mass flow rate unlike with thermal mass flow meters. The orifice meter typically produces error in flow measurements as much as 5 to 9% especially when you have changing pressure or temperature in the application. With inaccuracies of the flow measurement, the compressed air system may show a leakage of air from the outlet of the compressor to some changed value further downstream. This change seen by the “flow meter” may prove to be false information, so it’s important to use a technology like thermal mass flow that can measure with pin point accuracy throughout a wide flow range and not be affected by temperature and pressure swings.
SANITARY MASS FLOW METER APPLICATIONS
Our Inline Model # 600-9SAN mass flow meter (pictured to right) has provided good success in "Clean-in-Place", or CIP applications, as it is commonly referred to. The meter is capable of accurately and dependably measuring DI Water that is commonly used in this process. DI water has no conductivity and cannot be measured by all technologies effectively. Our Mass Flow technology is a good fit as it provides wide turndown on flow ranges, a wide temperature range, an unobstructed flow path, at a reasonable price point. We can manufacture custom Face to Face dimensions to fit existing process piping in sizes from 1/4" OD up to 4" OD sanitary tubing. The meter has standard 10 RA finished interior surface and is available with Tri-Clamp, VCO, or VCR type connections for ease of installation.
CIP is a process that is used in pharmaceutical, as well as other industries, to clean out and sterilize the process piping, vessels, or other equipment used in the manufacturing process. A typical sterilization process utilizes a mixture of DI Water (18 Megohm) and a caustic or solvent added to insure that the process piping is clean and sterile. This mixture is pumped through the entire process piping for a period of time and has to be measured in order to satisfy Good Manufacturing Processes set in place by the Food & Drug Administration.
Additional applications for mass flow meters are:
- Measure spray quantities of edible paints during the tablet coating process
- Measure air flow during the tablet compression stage
FOOD & BEVERAGE
Our thermal mass gas flow meters are used in the carbonation process in beverage manufacturing. Our in-line thermal mass flow meters have been used to measure the flow of chocolate and peanut butter during confectionary manufacturing. Our thermal mass flow meters are available with a sanitary 15 RA electro polished finish if necessary to support your manufacturing process.
Our UHP (Ultra High Pure) in-line thermal mass flow meters are used on UHP H2, N2, O2, Argon, and Silane distribution lines involved in the semi-conductor manufacturing process. Our UHP flow meters feature an electro polished finish that meets a 15 RA or better ID.
OTHER MASS FLOW METER APPLICATIONS:
MASS FLOW METER FOR MEASURING CARBON DIOXIDE GAS
The use of Carbon Dioxide Gas (CO2) and then how it is captured in industrial applications has been scrutinized over these past few years, with all the discussion of greenhouse gases. Thermal Instrument Mass Flow Meters have been used to measure the CO2 that is being used, and then re-captured in order to minimize GHG’s being released to the atmosphere.
Our mass flow meter In-line model # 600-9 with a variety of process connections and the ability to be placed in line sizes as small as ¼”, has been a reliable measurement instrument for our customers that are managing their CO2 usage. The in-line unit has negligible pressure drop (application dependent), high repeatability, and the accuracy needed to manage this process for many years. Our mass flow meters have been utilized in beverage manufacturing, power generation, and other manufacturing operations to name a few.
The Thermal Instrument Mass Flow Meter is available in standard 316 Stainless Steel for your industrial applications, and in a Sanitary (Model # 600-9SAN) design that meets the requirements of Food, Beverage, and Pharmaceutical manufacturers if necessary.
- Measuring the CO2 by-product at coal fired power plants for recovery, or to be sold as an additional product
- Measuring CO2 in the carbonization and bottling process in the beverage industry
- Food Processing for freezing or chilling, and packaging operations
- Injecting CO2 into the ground during hydraulic fracturing near or at the site of oil wells to draw out every last trace of crude oil
- As a raw material in the chemical industry
- Used to enhance algae production for nutritional and health sciences
- Cleaning the circuitry during the semiconductor manufacturing process removing impurities in place of chemical solvents
MASS FLOW METERS MEASURING FLARE GAS
MASS FLOW METERS OFFER SOLUTIONS FOR UPSTREAM OIL & GAS COMPANIES
Measuring the vent flare gas at the wellhead site provides critical data to oil and gas exploration companies. This quantifiable flow measurement provides the environmental compliance for government agencies, as well as operational data to provide insight into possible upset conditions. Additionally, this measurement provides the land owner and the state with important allocation production data.
Burning off waste gases through the use of a vent or flare system is quite common in the hydrocarbon industry like oil & gas (shale gas extraction), chemical, refining, natural gas plants, landfills, and even environmental waste treatment sites. The clear and resounding message from government agencies is that these emissions must be monitored and recorded down to the rate and totalized flow of these flare gases prior to exhaustion to the flare.
In order to make sure that these venting systems are operating properly, and in accordance with mandated guidelines, as set forth by the Environmental Protection Agency under 40 CFR 98 Sub Part W, it is required to have a flow metering system monitoring and measuring that vented gaseous emission out of the flare. One flow technology that presents itself as a viable and befitting solution for this measurement of vented or flared gas is our thermal mass flow meter.
GENERAL INFO ON MEASURING FLARE GAS
With vented and flared systems being used more and more to burn off waste gas from industrial production sites, the measurement of flow rate is vital to accommodating the regulatory agencies compliance rules. Flaring systems are used extensively in natural gas drilling, production and transmission, oil drilling and refineries, chemical processing plants as well as wastewater treatment, landfills and farming operations. Thermal Instrument Company’s line of thermal mass flow meters offers a reliable solution to these required monitoring and reporting activities, and brings companies into compliance for their reporting requirements. Our instruments offer high turn down, excellent repeatability, and rugged construction to stand up to the most extreme conditions.
MASS FLOW METER FOR MEASURING COOLING WATER
Our thermal mass flow meters are used to measure cooling water in the nuclear, oil refinery, petrochemical, and many other manufacturing industries. Cooling Water is used in manufacturing operations around the world to cool equipment because it is inexpensive and non-toxic. Cooling water can be recirculated allowing for repeated use and can be sourced from rivers, seas, municipal, or well-drawn sources making it an economical cooling solution.
Thermal Instrument manufactures a mass flow meter in both an insertion probe (Model # 62-9) and an in-line (Model # 600-9) unobstructed flow meter that can measure cooling water accurately and efficiently no matter the source. The Mass Flow Meter technology can even measure DI water because thermal mass does not measure the electrical conductivity of a fluid. Our in-line model # 600-9 thermal mass flow meter can be installed in line sizes ranging from as small as 1/4" OD to 4" and greater if necessary. Our in-line mass flow meter measures the lowest of flow rates with very negligible pressure drop to your application. The unobstructed path is a key feature to note, as pressure increases, motors and pumps have to work harder, increasing your operating costs from potential repairs and replacement of your infrastructure.
If your application has larger line sizes with flow rates in the thousands of gallons per minute than our insertion probe (Model # 62-9) may be a suitable alternative for your water measurement. Our insertion probes have been used in line sizes from 4" all the way up to 60" to accurately measure water flow and our engineering team will work with you to determine the proper solution that best fits your application. With the versatility of our insertion probe model, cooling water traveling through large pipe sizes can be measured very economically.
Thermal Instrument has been measuring liquids with mass flow meter technology for more than 50 years. We are one of the few calibration shops that are set up to measure liquids utilizing the thermal mass technology. Thus providing our customers with an economical alternative to other measurement technologies with the same high levels of accuracy, repeatability, and turn down that mass flow technology has delivered for years.
MASS FLOW METERS MEASURING NATURAL GAS TO BOILERS & FURNACES
Some states within the U.S. are requiring that any appliance including boilers have a flow meter to monitor the gas usage. Even if the gas usage for a particular location is only for the boilers, some state regulations as stipulated by the EPA, will not accept the reading from the local gas company’s meter set or their usage that is reported on the monthly usage bill. Some of these states and their zoned areas require that boiler operators document their log books with what the readings or usage is per unit at their site. Measuring this fuel flow is important for a monitoring and reporting standpoint and thermal mass flow technology is an ideal flow metering technique for both monitoring as well as reporting. To go one step further, many companies are utilizing thermal mass flow metering technology to determine optimal air-to-fuel ratios for monitoring air and fuel flow rates to burners. Thermal Instrument has both an insertion and in-line style thermal mass flow meter for this very application. Most of the customers are utilizing our insertion style flow meter for these piping lines. Mass flow rate is a more precise and reliable technique to measure gas flow than is a volumetric flow. The thermal mass flow technology also has a much broader operating flow range and a low pressure drop characteristic. Additionally, there is no pressure or temperature compensation on thermal mass flow technology so the result is a constant differential that is proportional to the gas mass flow rate. The beauty is that flow rate and temperature can be measured with one technology and provided as a dual analog output. Thermal Instrument Company provides a wide variety of installation type sensors and materials of construction for a host of different application conditions. The technology lends itself to offering a fast response time and there are no moving parts to wear out mechanically.
Many competitive style flow meters for this application are large in size with sizable pressure drops and installation restrictions with mounting location in the piping configuration. Installation of a thermal mass flow meter is relatively straight forward in the majority of applications. So if you have an application to monitor natural gas to your burner due to local, state, or federal regulatory mandates, or need to offer some control for air-to-fuel proportioning, then contact us today at (215) 355-8400 to discuss our solutions with you.
POWER / UTILITY
Our thermal mass flow meters measure #2 fuel oil used to fire boilers at steam stations in creation of electricity at power plants. Our in-line and probe model thermal mass flow meters have been used to measure both gas and liquids in the power creation process.
Our thermal mass flow meters are used in the refinery process of crude oil into a variety of petroleum products such as ethylene and propylene. Our meters are also used in the conversion of natural gas into methane, ethane, and propane.
Our thermal mass flow meters are used in measuring the raw materials used in chemical manufacturing as well as the finished product. We can meet UHP manufacturing conditions with our in-line electro polished 15RA ID thermal mass flow meter.