Interface or multiphase level measurements exist throughout the Oil & Gas streams as well as Petrochemical. While level measurement technologies have come a long way in effectively measuring liquids and solids, multiphase level measurement continues to be the biggest challenge and opportunity that exists today to which there is no perfect technology.
However, experience has shown that process optimization and increased uptime can still be achieved in many separator applications through reliable, best-in-class, level technology.
The objective of this paper is to review interface challenges, the current technologies being utilized for interface, field experience in various applications to achieve process optimization and increased uptime, and the future of reliable interface measurement.
DOWNLOAD THE TECHNICAL PAPER HERE
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A blog specializing in pressure, temperature, level and flow instrumentation, control valves, process analyzers, and all other areas of process measurement. Courtesy of Miller Energy, a New Jersey, New York, Pennsylvania, and Ohio process instrumentation Rep and Distributor.
Showing posts with label New York. Show all posts
Showing posts with label New York. Show all posts
ASCO Express Product Catalog
The ASCO Express program features a range of flow control products and accessories available for shipment the same day you order them. The products listed in this catalog provide the performance required for a variety of system and process applications including boiler, air handling, process control, and water and steam control. The control voltages available for each product are the primary voltages used in industrial and commercial applications today.
Download your copy of the ASCO Express Product Catalog here.
Contact Miller Energy for all your ASCO solenoid valve requirements.
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Temperature Switches
Temperature switch (United Electric Controls) |
A temperature switch detects the temperature of some substance. Temperature switches often use bimetallic strips as the temperature-sensing element, the motion of which actuates one or more switch contacts. An alternative design uses a metal bulb filled with a fluid that expands with temperature, causing the switch mechanism to actuate based on the pressure this fluid exerts against a diaphragm or bellows. This latter temperature switch design is really a pressure switch, whose pressure is a direct function of process temperature by virtue of the physics of the entrapped fluid inside the sensing bulb.
The “normal” status of a switch is the resting condition of no stimulation. A temperature switch will be in its “normal” status when it senses minimum temperature (i.e. cold, in some cases a condition colder than ambient). For a temperature switch, “normal” status is any sensed temperature below the trip threshold of the switch.
Like all other process switches, temperature switches exhibit a certain amount of deadband in their switching action. A temperature switch that trips at 300 F rising, for example, will not reset at 300 F falling. That switch would more likely reset at some lower temperature such as 295 F. With mechanical switch designs, some amount of deadband is inevitable due to friction inside the mechanism. However, process switch deadband is actually a useful characteristic as it helps avoid repeated “nuisance” alarms from happening.
To understand this concept, it is helpful to imagine a scenario where the process variable is at or very near the trip point. For our hypothetical temperature switch with a trip point of 300 F (rising), imagine a situation where the process temperature is precisely 300.0 F. Any further rise in temperature will of course trip the switch (sounding an alarm). With no deadband, however, the switch will immediately re-set when the temperature falls back down to 300.0 F. This means the switch may possibly “cycle” back and forth between its trip and reset states with just a minute change in process temperature (300.0 F to 300.1 F and back again). If the temperature switch is activating an alarm every time it trips, it will create a series of alarm events prompting operators to repeatedly acknowledge the alarm. This is a nuisance to operations personnel, as it distracts them from addressing what they already realize is a process problem. It is better for the switch to trip at 300.0 F rising and remain in that tripped state until the temperature falls down to some degree substantially below the trip point. This way, the operators only receive one alarm event rather than multiple alarm events for each process temperature excursion.
Some mechanical temperature switches come equipped with a separate adjustment for deadband (also called differential). Setting this deadband adjustment in a mechanical temperature switch requires the technician to repeatedly subject the sensing element to a rising and falling temperature, to check that the switch trips at the proper setting and resets at the proper setting. This is analogous to cycling the process variable back and forth when adjusting the “zero” and “span” settings of an analog transmitter: checking to see that the transmitter repeatedly outputs a 0% signal at the lower range value (LRV) and a 100% signal at the upper range value (URV).
For discrete temperature-sensing applications demanding high accuracy and repeatability, electronic temperature switch circuits using thermocouples, RTDs, or thermistors may be used instead of a mechanical (bi-metallic or filled bulb) sensing element. The operation and configuration of discrete electronic temperature switches is very similar to that of continuous electronic temperature transmitters.
An example of an electronic temperature switch module is the United Electric One Series shown below:
UE Series One Electronic Temperature Switch |
With electronic temperature switches, the adjustment of deadband (differential) is both precise and flexible. Unlike mechanical switches where deadband is primarily a function of friction, and therefore liable to change over time as the device wears, electronic switching circuits may be precisely set for any trip and reset points along its measurement range, remaining very stable over time.
For more information about temperature switches, contact Miller Energy by visiting https://millerenergy.com or by calling 908-755-6700.
Text adapted from "Lessons In Industrial Instrumentation" by Tony R. Kuphaldt – under the terms and conditions of the Creative Commons Attribution 4.0 International Public License.
How Do Pilot Operated Tank Relief Valves Work?
Storage tanks become pressurized when liquid is pumped in and compresses the existing tank vapor. Tanks also become pressurized due to increasing ambient temperatures, which cause the tank vapor to expand. To mitigate damage from these expanding tank vapors, pressure relief valves are installed on tanks to prevent structural damage resulting from over-pressure.
Here is an excellent animation, courtesy of Cashco, that shows how a pilot operated relief vent protects a storage tank from over pressurizing during a pump-in situation or during thermal heating conditions.
For more information on tank relief valves, contact Miller Energy at www.millerenergy.com or by calling 908-755-6700.
Here is an excellent animation, courtesy of Cashco, that shows how a pilot operated relief vent protects a storage tank from over pressurizing during a pump-in situation or during thermal heating conditions.
For more information on tank relief valves, contact Miller Energy at www.millerenergy.com or by calling 908-755-6700.
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Common Instrumentation Requirements for Industrial Boilers
Typical boiler instrumentation layout. (courtesy of Yokogawa) |
In order to ensure the air and fuel are combusted at an optimal ratio, the waste of fuel is eliminated, and the exhaust gas is cleaned, real-time monitoring of the oxygen concentration of combustion gases is required. Equipped with an oxygen sensor unit with a longer life span, the Zirconia Oxygen Analyzer ZR series are capable of measuring an oxygen concentration with high reliability. The Stack Gas Analyzer monitors exhaust gas components such as NOX, SO2, and CO2 in order to ensure low emission operation.
A single-loop controller can be used to properly distribute control functionality. Offering the advantages of flexibility of building distributed control systems, simple maintenance, compatibility with conventional systems, and the like, the YS1000 Series of Single-loop Controllers are ideal for safe and stable operation at low costs.
In order to ensure highly efficient and safely operated boilers, it is also indispensable to accurately monitor the drum level and steam flow rate. The EJA and EJX Series of Differential Pressure Transmitters are capable of measuring the drum level with high stability even in actual applications at high temperatures and high pressures. The DY Series MV TYPE of Vortex Flowmeters with a simple construction employ a built-in sensor to measure the steam mass flow with high reliability.
Yokogawa offers a wide variety of sensors and controllers that are used to monitor and operate boilers, and contributes to increasing the efficiency and environmental performance of boilers, as well as ensuring their safe and stable operation.
Recommended Products for Boiler Applications
- Drum Level Measurement - EJA/EJX transmitters
- Combustion Control - The YS1000 Dual CPU Loop Controller
- Steam Flow Measurement - Digital YEWFLO MV Type
- Combustion Monitoring - Zirconia Oxygen Analyzers and AV550G Multi Oxygen Sensor Converter
For more information in Eastern Pennsylvania, New Jersey, Metro New York or Delaware contact:
Miller Energy by visiting https://millerenergy.com or by calling 908-755-6700 in New Jersey, or 610-363-6200 in Pennsylvania.
Breakthrough Solenoid Valve Technology for Upstream Oil and Gas Heating Equipment
A white paper courtesy of ASCO Division of Emerson Automation
Fuel shutoff valves (ASCO) |
For valve manufacturers, these uses present a relatively specialized, rather challenging application. Environmental conditions at the point of use are often difficult. Ideally, valves should deliver reliable operation despite constraints on factors ranging from power consumption to service availability. Conversely, outdated controls can pose problems — including poor performance, noncompliance with current regulations, and triggering of environmental concerns.
In recent years, a new generation of solenoid valve technology has been changing the shutoff valve game. Their modern designs provide pipeline and tank heating systems with robust, durable performance; safety; and regulatory compliance — all while increasing efficiency and productivity.
Download the PDF version of "Breakthrough Solenoid Valve Technology for Upstream Oil and Gas Heating Equipment" here, or review it in the embedded document below.
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Miller Energy, Inc. - Expertly Serving These Industries in the Mid-Atlantic Region
Miller Energy is a Manufacturer's Representative and Distributor of Industrial Instrumentation and Process Control Equipment with offices in South Plainfield, NJ and Exton, PA. In business since Since 1958, Miller's success is attributable to their commitment to exceeding their customers expectations and a comprehensive line of "best-of-breed" measurement, control, and communication products. With a strong reputation for unparalleled customer service and expert local technical support, Miller Energy continues to demonstrate strong growth in the Mid-Atlantic region.
https://millerenergy.com
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https://millerenergy.com
908-755-6700 NJ
610-363-6200 PA
Industrial Refractometers Used in Process Control
Refractometer for pharmaceutical use (K-Patents). |
Process refractometers provide the analysis to quickly, reliably, and very accurately identify a sample and determine it's concentration and purity levels. They measure the refractive index and temperature of flowing liquids, and apply mathematical functions to determine the concentration of dissolved solids.
Common industrial refractometer applications are:
- Calculating beverages’ amount of sugar dissolved is water.
- In commercial food applications such as juice production or tomato processing, refractometers are used to measure degrees Brix (Tthe Brix scale relates refractive index to sugar concentration, and is a key way to maintain consistency).
- In the pharmaceutical industry, process refractometers are used to monitor and control concentration levels during supersaturation, a critical process in crystallization.
- In pulp and paper production, process refractometers for measuring dissolved solids in black and green liquor during the chemical recovery process.
For more information on industrial refractometers, contact Miller Energy by visiting https://millerenergy.com or by calling 908-755-6700 in New Jersey or 610-363-6200 in Pennsylvania.
Laboratory Flame Testing of Industrial Pressure Gauges: Wika vs. Competitor
Laboratory flame testing of industrial pressure gauges. Manufacturer Wika versus a competitor. The test is structured in (3) stages: a 10 second burn, a 30 second burn, and then a one minute burn. The Wika gauge maintains its reading, does not melt, and does not continue to burn.
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Flow & Pressure Instrumentation for Biopharmaceuticals & Life Sciences
Producing biopharmaceuticals is one of the world’s most demanding manufacturing processes.
Brooks Instrument’s mass flow and pressure control technology helps maximize cell culture yields and control bioprocess costs. Their flow
and pressure controllers set global standards for reliability, repeatability and long-term stability.
Brooks Instrument mass flow controllers (MFCs) satisfy key biotechnology research and production requirements:
Brooks Instrument’s mass flow and pressure control technology helps maximize cell culture yields and control bioprocess costs. Their flow
and pressure controllers set global standards for reliability, repeatability and long-term stability.
Brooks Instrument mass flow controllers (MFCs) satisfy key biotechnology research and production requirements:
- Tight control of DO and pH during experiments and production
- NO unplanned downtime due to high cost of losing a batch or experiment
- Ability to rapidly diagnose and resolve issues with bioreactors or fermentation equipment
- Cost-effective method for adhering to regulatory requirements
- Excellent technical support and rapid response for equipment service
To read the entire Flow & Pressure Instrumentation for Biopharmaceuticals & Life Sciences guide from Brooks Instrument, download it here. Alternatively, browse the embedded document below.
Cashco / Valve Concepts Model 3100 Packing Material Removal and Weight Installation Instructions
Valve Concepts Model 3100 |
The Model 3100 end-of-line conservation breather vent is designed for use on atmospheric and low-pressure storage tanks where pressure and vacuum relief is required.
How it Works
Weight loaded pallets in the vent housing allow the intake of air and the escape of vapors as the tank breathes due to thermal changes and product movement in and out of the tank. The pallets open and close to permit in breathing and out breathing necessary to maintain the tank pressure within permissible limits to avoid damage to the tank.
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Miller Energy - Industrial Instrumentation & Process Control Equipment
Miller Energy is a Manufacturer's Representative and Distributor of Industrial Instrumentation and Process Control Equipment. Since 1958, we have been committed to exceeding our customers expectations by providing an unparalleled level of customer service and local technical support. We offer the most comprehensive line of measurement, control, and communication solutions in the Industry today. The products we represent solve challenging applications in the Industrial Gas, Power, Refining, Chemical / Petro-Chemical, Food & Beverage, Water/Wastewater, and Pharmaceutical markets.
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Electronic to Pneumatic Converter
Component schematic using electronic controller and pneumatic control valve Image courtesy of Yokogawa |
Pneumatic signals are regularly used throughout many installations as matter of safety, legacy, or because a pneumatic signal can provide motive power to an operating device such as a valve positioner. Electrical control signals can be transmitted long distances across wires to deliver control signals to operating elements. The current to pneumatic converter provides a bridge between the two systems and allows the most beneficial aspects of each to be brought to bear on process operation.
Converters are available in standard variants that accommodate a number of hazardous location designations, as well as several output pressure ranges and calibrations. Share your process control connectivity challenges with application specialists, combining your own process knowledge and experience with their product application expertise to develop effective solutions.
Valves for LNG and CNG Operations
Valve specially designed for gas extraction operations has integral bypass which equalizes pressure across the valve prior to opening the main line, reducing torque requirements and piping stress. Courtesy Habonim |
Source and pipeline operations are faced with high pressure and extreme working environments. At various points along the distribution path, valves will be needed to regulate or direct flow and isolate portions of the system for safety or service. Emergency shutdown valves must be configured and installed to provide failure-proof reliability when called upon to operate. Transportation containers and equipment will utilize specialized valves adapted for the pressure, temperature, and reliability requirements of the application and industry. Additionally, some may need to survive fire conditions without failure.
Fueling stations for compressed natural gas employ valves that will endure cold temperatures produced by gas expansion, plus dynamic pressure cycling. Bubble tight shutoff is necessary to maintain safety.
Liquified natural gas (LNG) presents many of the same application challenges as pressurized gas, with the added element of cryogenic temperatures.
All of these applications can be adequately served with a properly selected and configured valve and actuator. Share your fluid flow control and valve challenges of all types with application specialists. The combination of your process knowledge and experience with their product application expertise will produce an effective solution.
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Water Quality Analysis – Constituent Survey Part 3
Water quality can be a concern for process input or effluent |
To conclude the three part series on water quality analysis in process control related industrial applications we examine silica, another element which in sufficient quantities can become a confounding variable in water for industrial use. In natural settings, silica, or silicon dioxide, is a plentiful compound. Its presence in water provides a basis for some corrosion-inhibiting products, as well as conditioners and detergents. Problems arise, however, when high concentrates of silica complicate industrial processes which are not designed to accommodate elevated levels. Specifically, silica is capable of disrupting processes related to boilers and turbines. In environments involving high temperature, elevated pressure, or both, silica can form crystalline deposits on machinery surfaces. This inhibits the operation of turbines and also interferes with heat transfer. These deposits can result in many complications, ranging through process disruption, decreased efficiency, and resources being expended for repairs.
The silica content in water used in potentially affected processes needs to be sufficiently low in order to maintain rated function and performance. Silica analyzers provide continuous measurement and monitoring of silica levels. The analyzers detect and allow mitigation of silica in the initial stages of raw material acquisition or introduction to prevent undue disruption of the process. Additionally, a technique called power steam quality monitoring allows for the aforementioned turbine-specific inhibition – related to silica conglomerates reducing efficacy and physical movement – to be curtailed without much issue. The feedwater filtration couples with a low maintenance requirement, resulting in reduced downtime of analytic sequences and a bit of increased peace of mind for the technical operator.
While silica and the other compounds mentioned in this series are naturally occurring, the support systems in place to expertly control the quality of water is the most basic requirement for harvesting one of the earth’s most precious resources for use. As a matter of fact, the identification and control of compounds in water – both entering the industrial process and exiting the industrial process – demonstrates key tenets of process control fundamentals: precision, accuracy, durability, and technological excellence paired with ingenuity to create the best outcome not just one time, but each time.
Q&A for Ultrasonic Level Switches
Ultrasonic level switches with single and multiple level measurement points Courtesy Magnetrol International |
A previous article , with an accompanying video, provided some comparison between the two detection methods. Here is the operational difference summarized. A vibrating tuning fork device monitors the resonant frequency of the vibrating fork and responds when the frequency shifts due to immersion of the fork in liquid. An ultrasonic level switch transmits an ultrasonic pulse across a gap, measuring the intensity of the received signal and determining whether the signal passed through liquid (high level received signal) or air (low level received signal). While both technologies are effective, the ultrasonic level switch can be applied over a wider range of liquid density and does not require recalibration or adjustment for a change in media density.
Magnetrol International, globally recognized innovator in level measurement technology and instruments, recently answered a few application questions in their blog about their Echotel ultrasonic switches. The questions, along with answers penned by Magnetrol's product manager Tom Kemme, are shared here.
Question: Can ECHOTEL be used in applications that have entrained air?
Answer: Yes, ECHOTEL ultrasonic switches can be used in applications that have entrained air. All ECHOTEL gap switches feature a tip-sensitive transducer that provides superior performance over side gap transducers that are offered by other companies. Side gap transducers allow gas bubbles to adhere to the upper surface of the gap, which cause false dry gap alarms. Tip sensitive transducers allow these bubbles to pass through the gap. Applications with severe turbulence or entrained air should use the Model 961 switch, which offers a time delay adjustment. Up to 10 seconds of delay can be used to disregard entrained air and reliably detect the true liquid level.
Question: We are considering adding level alarm switches to our process to provide high-high level indication in several tanks. Instead of switches with relay outputs, we are considering the current shift output. What are the advantages of a current shift output?
Answer: Current shift electronics simply shift the current output from 8 mA when the level switch is in the normal operation, to 16 mA to indicate a level alarm. ECHOTEL Model 961 also has a user selectable fault signal of 3.6 or 22 mA. Current shift switches are 2-wire loop powered, which allows them to be offered with intrinsically safe approvals. This allows these switches to be put into hazardous area locations at a lower cost since rigid conduit is not necessary. Since current shift switches provide constant indication of either a normal (8 mA), alarm (16 mA), or a fault (3.6 or 22 mA) condition, they are sometimes referred to as a transmitter for the price of a switch.
Share your level measurement requirements and challenges with process measurement specialists, combining your own process knowledge and experience with their product application expertise to develop effective solutions.
Applying Coriolis Flowmeters
Coriolis Flowmeter Courtesy Yokogawa |
- Directly measure mass flow based on the principle of measurement.
- No "moving" parts (except the slightly vibrating sensor tubes).
- Coriolis sensors have the ability to measure flow of non-conductive fluids.
- Measure the mass flow rate with high accuracy.
- Instruments can be applied across a wide usable measurement range.
- Deliver density measurement based on oscillating frequency.
- Not materially impacted by fluid viscosity or density.
- Coriolis flow meters also do not need lengthy straight pipe sections upstream or downstream of the sensing unit.
SELECTION AND INSTALLATION RECOMMENDATIONS
- Rapid temperature changes within the measured medium can impact measurement accuracy.
- Wide ranges of connection types are available, specify the best match for your system.
- Select sensor tube construction material to accommodate media characteristics.
- For liquid measurement, the sensor tube will extend downward from a horizontal pipe run.
- As with most industrial products, there may be restrictions on where the device may be used. For example, not for use in aircraft. Assure that your application conforms with the intended usage of the instrument.
- Install at least one tight shutoff valve adjacent to the instrument for purposes of zeroing. Isolation valves for inlet and outlet are preferred.
- Follow manufacturer recommendations for pipe supports, if required, at inlet and outlet sides of the unit
- Avoid installation at locations with high levels of vibration or strong electrical fields.
- Locate the sensor unit at the lowest practical level in the piping system. This helps avoid collection of gas bubbles in the sensor tubes.
- Sensor tubes need to be completely filled with subject medium to obtain accurate measurement.
- Avoid the use of flexible connections and reducers at the unit connection points, unless in accordance with specific manufacturer guidelines.
Share your process instrumentation challenges and requirements with process measurement specialists, combining your process knowledge and expertise with their product application experience to develop effective solutions.
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Specialty Valves for Biotech and Pharma Applications
Stainless steel ball valve for sanitary applications Courtesy Habonim USA |
One manufacturer, Habonim, a globally recognized manufacturer of high quality ball valves, offers a complete line of ball valves specifically designed for sanitary process applications.
The TuBore™ valve series is available in line sizes from 1/4" to 6" with clamped or welded connections and available with manual operator, pneumatic or electric actuation.
The datasheet included below provides more detail and specifications. Share your sanitary fluid process control requirements and challenges with product specialists. Combining your process knowledge with their product application expertise will produce effective solutions.
Succeeding: Engineer as Peacemaker
Make Allies, Not Adversaries |
Let's take a step away from the technical, but still focus on an important aspect of our work.
As engineers involved in process measurement and control, we are accustomed to everybody else looking to us for answers and solutions. We are the people that make things work. Occasionally the pressure and stress can get a little intense and strip away some of our civility in our dealings with those around us. You may have bitter experience with this as either victim or perpetrator. It never ends well. With a private and candid self-assessment about how we view and interact with other stakeholders in our projects, we may be able to scale down some of our stress and better focus on the reality of the task at hand. Consider the points below. Comment and add a few points of your own.
You are an expert, but so are they.
Everybody else's job usually looks easier than it really is.
All jobs have their own special challenges and responsibilities that generate stress. Accept the notion that you probably do not fully comprehend the burdens on those around you. Your portion of the project is certainly critical, but no more so than that of anybody else. Everybody needs to perform or nobody succeeds. Try not to view your project tasks as compartmentalized, but rather as part of the combined joint effort of all stakeholders. Help out others whenever you can. Again, make allies.
Everybody is somebody's customer.
Whomever you deliver your work product to is your customer. The people delivering their work to you should view you as their customer. Make your customers happy by adjusting aspects of your procedures to better satisfy their needs. In a more technical sense, your modified process output becomes an improved input to their process. Small changes in your delivery may produce comparatively large returns in customer satisfaction. Allies.
Do not embarrass or demean others...especially in public settings.
Embarrassment breeds anger, a desire for revenge, and other bad and unproductive things. Avoid words and deeds that will make a coworker or stakeholder look bad in front of others. If there is a problem, if there is a mistake, try to deal with it discreetly whenever possible. Giving a someone a chance to repair a mistake before it becomes public builds value in your relationship. Certainly, there can be instances where more is at stake than someone's pride. Use good judgement to recognize when you can privately give someone an opportunity to amend a situation without causing harm.
Reach a common understanding of project scope and technical details
It's not about being right. It's about being successful.
At our company we recognize customers are more than merely people that buy things from us. They are people to whom we contribute our time and talent to help achieve their success,... which inevitably will lead to ours. Never hesitate to let us know how we are doing, or how we can help.
Miller Energy - Industrial Instrumentation and Process Control Solutions
Miller Energy is a Manufacturer's Representative and Distributor of industrial instrumentation and process control equipment. Miller is committed to exceeding customers expectations by providing an unparalleled level of customer service and local technical support.
Miller offers the most comprehensive line of measurement, control, and communication solutions in industry today. The products provided by Miller solve challenging applications in the industrial gas, power, refining, chemical / petro-chemical, food & beverage, water/wastewater, and pharmaceutical markets.
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