Solenoid Valves - The Operational Basics

Industrial Solenoid Valves
Magnatrol

A solenoid is an electric output device that converts electrical energy input to a linear mechanical force.

At the basic level, a solenoid is an electromagnetic coil and a metallic rod or arm. Electrical current flow though the coil produces a magnetic field, the force of which will move the rod. The movable component of the solenoid is linked to, or part of, the operating mechanism of another device. This allows the switched electrical output of a controller to regulate mechanical movement in another device and cause a change in its operation. A common solenoid application is the operation of valves.

A plunger solenoid contains a movable ferrous rod, sometimes called a core, enclosed in a tube sealed to the valve body and extending through the center of the electromagnetic coil. When the solenoid is energized, the core moves to its equilibrium position in the magnetic field. The core is also a functional part of valve operation. It's repositioning causes a designed changed in the valve operating status (open or close). There are countless variants of solenoid operated valves exhibiting particular operating attributes designed for specific types of applications. In essence, though, they all rely on the electromechanical operating principle outlined here.

A solenoid valve is a combination of two functional units.

• The solenoid (electromagnet) described above.
• The valve body containing one or more openings, called ports, for inlet and outlet, and the valve interior operating components.

Flow through an orifice is controlled by the movement of the rod or core. The core is enclosed in a tube sealed to the valve body, providing a leak tight assembly. A controller energizing or de-energizing the coil will cause the valve to change operating state between open and closed, regulating fluid flow. There are almost countless variants of solenoid operated valves, specifically tailored for applications throughout industrial, commercial, and institutional operations.

The document provided below illustrates a portion of the broad array of solenoid valves available for industrial control applications. There are also some good cutaway illustrations showing the internal operating valve parts. Share your valve requirements and challenges with an application specialist. Combining your process application knowledge with their product expertise will produce effective solutions.

Industrial Solenoid Valves, Bronze and Stainless Steel from Miller Energy, Inc.

Use Electronic Pressure Controllers in Your Research Process Loop to Eliminate Droop, Boost, and Hysteresis

(re-blogged with permission from Brooks Instrument)

Gas pressure control is critical in many applications like life sciences and chemical/petrochemical research where flow is an integral part of the process. Brooks Instrument electronic pressure controllers can be used as they require flow to function. Compared to using a mechanical pressure regulator, electronic pressure controllers eliminate droop, boost and hysteresis, offering stable pressure control.

There are two configurations available for pressure control – upstream and downstream. This terminology is somewhat unique to Brooks Instrument electronic pressure controllers.

Downstream vs. Upstream Pressure Control

Downstream pressure controllers maintain the pressure downstream of the device itself, increasing flow to increase the pressure and decreasing flow to decrease the pressure. For this reason, this is called direct acting. This configuration is commonly called a standard pressure regulator. A downstream pressure controller acts very similar to a typical mass flow controller because they are both direct acting.

Upstream pressure controllers maintain the pressure upstream of the device itself, increasing flow to reduce the pressure and decreasing flow to increase the pressure. For this reason, this is called reverse acting. This configuration is commonly called a back pressure regulator in the industry.

Selecting and Sizing an Electronic Pressure Controller

The following information is required to select and size a Brooks Instrument electronic pressure controller:

• Process gas
• Maximum flow rate being used to maintain pressure -The “sweet spot” for pressure control is between 100 SCCM and 5 SLPM.
• Calibration pressure (maximum pressure to be controlled)
• Reference pressure (for upstream controllers the reference pressure is the downstream pressure and for downstream controllers the reference pressure is the upstream pressure)

As long as flow is present in a process you will typically find the need for some type of pressure control. Vessel sizes up to 30 liters commonly use flow rates up to 3 SLPM during their process steps. Brooks Instrument pressure controllers are a perfect fit for these services, offering stable pressure control with no droop, boost or hysteresis, which are commonly experienced when using a mechanical pressure regulator.

Typical Bioreactor Process Using an Upstream Pressure Controller

Magnetic Liquid Level Gauges

Magnetic level indicator with supplemental
guided wave radar instrument
Gemini Model - Magnetrol

Magnetic liquid level gauges are an excellent alternative to sight glass level gauges for many process measurement applications. Their reliable performance and adaptability has made them the primary choice in a wide variety of industrial settings.

Essentially, a magnetic level gauge or magnetic level indicator, is a sight glass with enhancements that provide better readability and a form factor that enables the inclusion of additional level monitoring functions on the same device. Where a sight glass requires operator proximity to read liquid level, the magnetic level gauge's indicating scale, or flags, can be clearly viewed from a considerable distance. A sight glass gauge can also be hindered by difficulties in visually determining liquid level because of deterioration of the glass surface or properties of the liquid. Magnetic level gauges remove the need to observe the liquid directly by incorporating a float device within a tube connected to the liquid containing vessel. As the float moves in response to liquid level changes, its magnet causes the indicator flags on the scale to rotate and display either a black face to indicate no liquid present, or a colored face.

Magnetic level indicators are available with numerous options, including armored casings to protect the tube and float arrangement and limit switches to signal the attainment of specific level conditions. Combining a MLI with another level measurement technology, such as guided wave radar or magnetostrictive, can provide an analog process signal representing liquid level and serve as a redundant measuring device for critical applications.

The document included below provides illustrated detail about the devices and their proper application. Share your process measurement requirements and challenges with instrumentation experts. The combination of your process knowledge and their product application expertise will produce effective solutions.

Magnetrol Orion Magnetic Liquid Level Indicators from Miller Energy, Inc.

Comparison of RTD and Thermocouple for Process Measurement

Industrial Temperature Sensor
Courtesy Wika

Proper temperature sensor selection is key to getting useful and accurate data for maintaining control of a process. There are two main types of temperature sensors employed for industrial applications, thermocouple and resistance temperature detector (RTD). Each has its own set of features that might make it an advantageous choice for a particular application.

Thermocouples consist of a junction formed with dissimilar metal conductors. The contact point of the conductors generates a small voltage that is related to the temperature of the junction. There are a number of metals used for the conductors, with different combinations used to produce an array of temperature ranges and accuracy. A defining characteristic of thermocouples is the need to use extension wire of the same type as the junction wires, in order to assure proper function and accuracy.
Here are some generalized thermocouple characteristics.

• Various conductor combinations can provide a wide range of operable temperatures (-200°C to +2300°C).
• Sensor accuracy can deteriorate over time.
• Sensors are comparatively less expensive than RTD.
• Stability of sensor output is not as good as RTD.
• Sensor response is fast due to low mass.
• Assemblies are generally rugged and not prone to damage from vibration and moderate mechanical shock.
• Sensor tip is the measuring point.
• Reference junction is required for correct measurement.
• No external power is required.
• Matching extension wire is needed.
• Sensor design allows for small diameter assemblies.

RTD sensors are comprised of very fine wire from a range of specialty types, coiled within a protective probe. Temperature measurement is accomplished by measuring the resistance in the coil. The resistance will correspond to a known temperature. Some generalized RTD attributes:

• Sensor provides good measurement accuracy, superior to thermocouple.
• Operating temperature range (-200° to +850°C) is less than that of thermocouple.
• Sensor exhibits long term stability.
• Response to process change can be slow.
• Excitation current source is required for operation.
• Copper extension wire can be used to connect sensor to instruments.
• Sensors can exhibit a degree of self-heating error.
• Resistance coil makes assemblies less rugged than thermocouples.
• Cost is comparatively higher

Each industrial process control application will present its own set of challenges regarding vibration, temperature range, required response time, accuracy, and more. Share your process temperature measurement requirements and challenges with a process control instrumentation specialist, combining your process knowledge with their product application expertise to develop the most effective solution.

Ultrasonic Contact Level Switches Provide Reliable Overfill Protection

Echotel® Ultrasonic Level Switches

Magnetrol

Requirements for safety regulation compliance continue to grow. Business operators want increased levels of risk aversion and contingency management. In industrial settings where fluids are processed or stored, meeting these goals calls for new layers of protection and redundancy for existing layers.

Tank overfill is a serious concern of any fluid processor. Providing multiple methods of measuring tank or vessel fluid level provides substantially greater assurance against overfill. One scheme involves using a continuous level measurement instrument, such as guided wave radar, to provide the real time tank level signal and an ultrasonic level switch as a tank overfill indicator.

The operating principal of an ultrasonic level switch is quite simple. A transducer sends an ultrasonic pulse across a gap. When liquid media is present in the gap, the sound wave is transmitted with little attenuation across the gap and detected. When liquid media does not fill the gap, the sound wave is strongly attenuated and fails to transmit across the gap.

Tuning fork level switches are commonly applied as the overfill detection device, but Magnetrol, a recognized global innovator in level measurement, feels they have a better solution with their Echotel® ultrasonic level switches. The video below provides an illustration of how the ultrasonic level switches can be applied, as well as a comparison between ultrasonic and tuning fork methods.

Share your level measurement requirements and challenges with a product application specialist. The combination of your process expertise and their product application skill will produce an effective solution.

Use Manifold Valves With Pressure Transmitters

Manifold Valves for Pressure Gauges and Transmitters
Pentair - Anderson Greenwood

Pressure transmitters are generally fixed in place, but require regular access for calibration and operational testing. Unlike instruments used to measure some other process conditions, a pressure transmitter is directly connected to the process, making it's removal problematical. Manifold valves provide a compact and effective means of access and isolation needed to perform regular maintenance and calibration operations while maintaining the pressure transmitter in place.

A single pressure transmitter or gauge can be served by a simple 2-valve manifold. One valve provides isolation of the instrument from the process. The second valve opens to atmosphere on the instrument side of the isolation valve. This allows the pressure transmitter or gauge to be isolated from the process and connected to a calibration source. Here is a schematic example.

Certainly, any qualified technician can cobble together this arrangement from a pile of valves and fittings. The advantages of using a manifold valve are several.

• High pressure rating
• Reduced leakage potential
• Compact size
• Comparatively rapid installation

There are numerous manifold valve configurations to accommodate any valve and gauge requirement. Manifold valves can also be used in other applications for making effective and convenient connection arrangements between instruments and processes. Share your connectivity challenges and requirements with process instrumentation specialists, combining your process knowledge with their product application expertise to develop the best solutions.

Thermal Dispersion Flow Meter For Compressed Air and Nitrogen Measurement

Thermal Dispersion Flow Meter
Magnetrol

Monitoring compressed air usage in a factory or other operation where it is consumed is essential for proper system maintenance and attainment of energy efficiency goals. The ability to track down leaks and monitor compressed air usage enables stakeholders to work toward maximizing the return on an asset with substantial initial and operating costs.

Easy installation and simplicity of operation are advantages for any instrument applied in this manner, making compressed air flow measurement a good application for a thermal dispersion flow meter. With no moving parts and a simple operating principal, a thermal dispersion flow meter can be quickly installed and put into operation. A digital display of the flow measurement provides local information, and a networking connection or other signal output can provide for remote or centralized monitoring and data collection.

A cut sheet is included below that provides detail on technological, operational, and installation aspects of this simple and effective instrument. Share your flow measurement challenges with application experts, combining your own process knowledge with their product application expertise to develop cost effective solutions.

Thermal Dispersion Mass Flow Measurement from Miller Energy, Inc.

Setting Up the United Electric Controls Series One Safety Transmitter

Here is a two part tutorial showing how to setup your United Electric Series One Safety Transmitter. If you need any additional help or product information, reach out to a product specialist.

Part One Video

Part Two Video

Safety Transmitters For Temperature and Pressure

Series One Safety Transmitter
United Electric Controls

Industrial history is replete with examples of catastrophic accidents. New safety technologies exist today that can prevent or mitigate mishap and disaster in fluid processing and other operations. Modern philosophy of plant safety brings a focus on a proactive approach. Process operators have a new sense of urgency to bring increased levels of safety to their operations.

The United Electric Controls (UE) Series One is a SIL-certified (Safety Integrity Level) transmitter designed solely for safety, alarm, and shutdown. With reliability, speed, and reduced nuisance trips an integral part of its design, the Series One is suitable for application in new installations, or easily integrated into existing operations.

A typical safety loop consists of sensors (such as a pressure or temperature transmitter), controllers, and final control elements. Most SIL-rated pressure transmitters require 300ms to communicate with the controller, then up to 500ms for the controller to send a signal to the final control element (such as a valve). This combined response time may insufficient for some applications. Incorporating the One Series Safety Transmitter, directly connected to the final control element, the total signal time is reduced to 100ms - a large and significant time savings when safe operating conditions have been breached. When used with blowers, pumps and compressors, the One Series makes up a complete safety system with a self-contained sensor, controller, and final control element (the switch) capable of SIL2 without additional safety instrumented function (SIF) components.

The below document provides detailed information about the Series One. Share your process safety challenges with the instrumentation specialists and combine your process knowledge with their product application expertise to produce effective solutions.

Safety Transmitters for Temperature and Pressure from Miller Energy, Inc.

Opportunity For Improving Power Plant Heat Rate

Opportunities for improving efficiency at power plants

The large scale of most power plants provides a environment in which financial justification, or payback, of attempts to improve energy consumption can be justified. Even small improvements in efficiency can yield very substantial returns. The challenge to engineering and management is to select the projects which have the best overall probability of success and can be integrated into the process with the least amount of disturbance.

One area of the steam cycle that may be a candidate for improvement is the feedwater heater. This device is essentially a shell and tube heat exchanger used to recover waste heat from the process and use it to preheat boiler feedwater. Maintaining the correct liquid level in the feedwater heater is a key element of extracting maximum performance. Magnetrol, a globally recognized leader in the development of level measurement equipment, has produced a video showing how their technology can be used in an advantageous manner to others in regulating feedwater heater liquid level and achieving maximum efficiency.

Handbook on pH and ORP Measurement

Dual input pH analyzer and transmitter
Courtesy Yokogawa

Measurement of pH/ORP is a common operation throughout a number of industries. Obtaining true measurements and making correct interpretation of the results can prove challenging without solid working knowledge of the methodology and procedure involved. Certain effects have the ability to cause problems if not taken into consideration.

The book provided below, authored and provided by Yokogawa Electric Corporation, provides a comprehensive understanding of pH/ORP measurement and how to achieve reliable results. Basic information on the principles of measuring pH/ORP, construction of the sensing elements, and their basic use in process applications is provided.

A part of achieving accurate and reliable pH/ORP measurements includes the provision of sufficient electrode strorage conditions and proper maintenance. Prevention of common errors during maintenance and storage, as well as consistent detection of loop failures is important. This book describes how to avoid pitfalls and detect failures.

The book is accompanied with a frequently asked question and answer section as well as an appendix that includes helpful information like a Chemical Compatibility Table and a Liquid-Application-Data-Sheet, which can be used to describe the user’s application.

pH and ORP Measurement Handbook from Miller Energy, Inc.

Miller Energy Introductory Video

Miller Energy is a Manufacturer's Representative and Distributor of Industrial Instrumentation and Process Control Equipment. Since 1958, Miller been committed to exceeding our customers expectations by providing an unparalleled level of customer service and local technical support. Miller Energy maintains two office locations in NJ and PA. The South Plainfield, NJ operation services the areas of Northern NJ, New York, and Fairfield County Connecticut and serves as our corporate headquarters. The Exton PA office serves the areas of Southern NJ, Eastern PA, Delaware and Maryland.

Safety Transmitters Achieve Safety Goals With Reduced Cost and Complexity

Series One Safety Transmitter
United Electric Controls

Process safety experts continually seek sustainable ways to improve the performance of safety critical loops, achieving risk reduction and safety goals in a cost-effective manner. Some view a reduction in complexity of safety related protocols to be a positive development. Traditional or historical approaches to deploying full blown safety systems were generally associated with great expense and high complexity, and still came up short on delivering the needed levels of risk reduction. Process control device and equipment manufacturers have responded with newer technologies and products that better address the safety needs of industrial processing.

In sensor subsystems, United Electric’s certified safety transmitter for pressure or temperature provides a less costly, simple path for process designers, instrument and control engineers, and maintenance personnel. The Series One Safety Transmitters combine several useful safety and monitoring functions into a single, easy to deploy device. Products are available for gauge pressure, differential pressure, and temperature applications. In addition to a 4-20 mA process variable output, the Series One has an embedded programmable high-capacity relay certified as a safety variable output. The Series One Safety Transmitter provides designers the option of a hard wired trip in less than 100 milliseconds, with a tenth of a percent repeatability, along with the monitoring functions of a traditional continuous analog output.

For equipment under control requiring protection, or processes where rapid excursions can initiate dangerous events, this unique pressure and temperature transmitter is addressing process safety time constraints, coupling issues with PLC and DCS units, and adding diversity to the safety instrumented function.

There is a whole lot more to learn about these "Safety right out of the box" industrial pressure and temperature safety transmitters. A product data sheet is provided below, but you can get the latest and most detailed product and application information from a specialist in industrial process measurement and control. Share your safety instrumentation challenges with them, combining your process expertise with their product application knowledge to develop effective solutions.

United Electric One Series Safety Transmitter from Miller Energy, Inc.

Yokogawa Data Acquisition Unit Product Changes

The DX1000 and DX2000 are among the potential
replacements for the discontinued CX Series

Modern industrial process control has ever increasing demands for data acquisition. The ability to rapidly gather and process measurements into control and management decisions and reports is essential to efficiency, safety, and profitability. Yokogawa has been a leading manufacturer in the data acquisition sphere for decades, and has made some changes in its product line to maintain its leadership position.

The model CX 2000 was discontinued at the end of February. It combined data acquisition, display, control, and networking in a single unit. A scaled down version, CX 1000 was previously discontinued. The company recommends possible replacements to include one or more of the following products:

• Advanced Application Temperature Controller UT75A
• Button Operated DX1000/DX2000
• General Purpose Temperature Controller UT35A/UT32A
• Mid-level Temperature Controller UT55A/UT52A
• TC10 Temperature Controller
• Touch Screen GX10/GX20
• US1000 Digital Indicating Controller
• UTAdvanced UT32A-D
• UTAdvanced UT32A-V/C/R

The DX2000 Daqstation is a mature product with a solid portfolio of field installations. It can accommodate display, recording, networking, and storage of data on up to 48 input channels. Input types include DC voltage, contact signal, RTD, and thermocouple. Ethernet connection enables remote access via a website and the unit can provide email alerts. There are numerous effective and user-friendly features included with the DX2000, which incorporates Yokogawa's decades of experience with recording and data acquisition.

Whatever your data acquisition needs and challenges, the best solutions will result from combing your process expertise with the knowledge of a product specialist. Reach out to them and get results.

Data Acquisition Equipment for Automation and Process Control from Miller Energy, Inc.

Energy Calculator Simplifies Chilled and Hot Water Usage Monitoring

Yokogawa Model 212 Heat Calculator

Early in my professional career, I was a sales rep calling upon building engineers, maintenance technicians, and lots of HVAC related people. One encounter I had, many years ago, has always stayed with me. I was prattling on to a building engineer about whatever gear I was trying to promote for his chilled water system, and I must have really missed the mark. The engineer, clearly a man of superior experience to mine, stopped me in mid sentence. "You know what flows through these pipes?", he said, referring to the chilled water system. In my defense, I was very young and inexperienced at the time, but I did answer "Chilled water". My building engineer friend bellowed out, "Wrong....money flows through those pipes". That single encounter had a lasting impact upon how I viewed HVAC systems.

Energy costs for heating or cooling a building can be the single largest line item on the cash outflow summary for an operation. Much effort and expense is put into efforts to maximize energy efficiency and conservation. Monitoring of usage patterns related to the chilled or hot water system can provide useful information for developing new conservation strategies and verifying the impact of any steps taken to reduce consumption.

The Yokogawa Model 212 is an affordable and easy to install and use device that will provide a stream of usage data. A key feature of the Model 212 is its ability to interface with a broad range of flowmeter devices, including vortex and magnetic flowmeters with pulse outputs, positive displacement and inferential water meters, turbine and paddlewheel flowmeters. This flexibility allows the user to select a companion flowmeter that will suit their accuracy, budget, and operational requirements.

The Heat Calculator has four modes of operation to totalize the usage patterns in a manner that best suits the needs of the user. Additionally, the unit can interface with a building management system and includes internal data logging capabilities. Other features are described in the product data sheet I have included below.

Even small chilled and hot water systems can benefit from usage data derived from a monitoring system such as the Yokogawa Model 212. Share your system challenges with a product specialist. Combining your process and system knowledge with their product application expertise will produce effective solutions.

Heat Calculator for Chilled and Hot Water Systems from Miller Energy, Inc.

Bimetallic Thermometers With Adjustable Angle and Rotating Head Make Installation Simple

Bimetallic Thermometer
Courtesy US Gauge

A bimetallic thermometer relies on the deformation of a bimetal spring or strip in response to a given temperature. The mechanical deformation is transformed into rotational movement of the indicating needle on the instrument face, where the corresponding temperature can be read by a technician or operator. This design principle has been in use throughout laboratories, kitchens, and industry for many years and has proven to be predictably accurate, stable, and rugged.

The major advantages of the bimetallic thermometer are its relative cost, ease of use, and ability to function without any power source. While this class of instruments provides operability up to +1000°F, the operating principle does not tend to provide similar accuracy at very low temperatures.

When applying dial faced thermometers, the main considerations beyond selecting the appropriate temperature range are the diameter of the dial and the mounting arrangement. US Gauge, an Ametek brand, provides a line of bimetallic thermometers for industrial process applications with a large degree of built-in flexibility to make selection and installation very simple. Three and five inch dial faces are offered, along with a selection of temperature ranges and stem lengths. The stem can be adjusted to almost any angle to provide good view of the face, and the head can be rotated over 180°.

Provided just below is a data sheet and description of the ADJ Series from US Gauge. Share your instrumentation challenges with the product application experts at Miller Energy. Combine your process knowledge with their product expertise and develop the the best solutions.

Industrial Bimetallic Thermometers: 3 and 5 Inch Adjustable Angle from Miller Energy, Inc.

Specialty Enclosures Complete Instrument and Equipment Installations

Analyzer Cabinet
Courtesy Intertec

Industrial environments present a wide range of challenges to the process designer or operator looking to install sensitive instrumentation or controls. Not all devices come with integrated enclosures suitable for all environments. The responsibility for properly housing equipment, controllers, and other instruments can fall on the process designer or operator.

There are numerous considerations in the design and selection of an enclosure, especially when the application drifts beyond the range of commonly available sizes, configurations, and materials of construction. Here are some thinking points for you.

Instrumentation safely housed
while clearly visible to operator
Courtesy Intertec

• Ignition Hazard Level: Areas or locations with hazardous classifications will require special enclosure designs and features for compliance.
• Climate: If outdoors, consider the range of local weather conditions and their potential impact on the longevity and performance of the enclosure, its ability to protect whatever is housed within.
• Access: Do operators need quick access to contained equipment? If so, appropriate latches or other closures that allow interior access without a need for tools may be in order. Security concerns may warrant locking capability. A clear panel installed in a door can provide visual access to instruments safely contained within the enclosure.
• Corrosion: Wet environments or locations near seawater or other corrosive elements can call for upgraded coatings or materials of construction that will prolong the useful life of the enclosure.
• Enclosure Cooling or Heating: Depending upon the surrounding temperature or the characteristics of equipment housed in the enclosure, heat removal or supplementing accessories may be integrated into the enclosure design.
• Size: Consideration given to possible additions to the original array of instruments or devices to be contained can save substantial time and money if a future expansion is in order. The size of the enclosure should provide for any clearance  recommended by device  manufacturers for their installed components. Provide adequate servicing space for field technicians to perform any necessary tasks related to housed equipment.
• Penetrations: Conduit or other penetrations required for proper operation and installation can be accomplished more precisely, and often at a lower cost, in the factory than in the field. Carefully laying out and coordinating the installation of connections to the enclosure can save time and trouble in the field.

Certainly, there are numerous other elements of enclosure design that may be taken into account for differing installation requirements. Share your project requirements with application specialists and reach the best solutions by combining your process knowledge with their product expertise.

Simplifying Plant Safety Instrumentation

Series One Safety Transmitter and Switch
Courtesy United Electric

Safety implementation typically is accomplished by a group that includes plant instrument engineers and technicians. They are charged with developing simple and reliable solutions that increase safety and reduce risk. Safety related events can involve the question of when to shut a process down. These decisions can hinge on the level of key process variables such as flow, level, temperature and pressure. All must be within their specified range at various locations throughout the process, whether within chemical and petrochemical plants, refineries and power plants, or other processing operations. Critical points of measurement can include anything from process vessels to eye wash stations.

For such point safety applications, a properly designed and implemented digital switch with self-diagnostics can be an important part of the answer. As an element of a multiple technology solution, a digital switch-based approach can help eliminate common-mode failures, significantly improve response time, achieve needed safety integrity levels (SILs), and simplify plant safety instrumentation.

United Electric Controls has authored a white paper entitled "Simplifying Plant Safety Instrumentation" that provides some insight into deployment of safety controls. The entire white paper is included below and will prove to be useful reading. More detailed product and application information is available from product specialists. Combining their product expertise with your process knowledge will produce the best solutions.

Simplifying Plant Safety Instrumentation from Miller Energy, Inc.

"Bubbler Method" Liquid Level Measurement

An accurate pressure transmitter
is an integral part of  a liquid level
measurement system using the
"Bubbler Method"
Courtesy Brooks Instrument

Measuring liquid level in a tank or vessel can be accomplished in a number of ways, all of which require some arrangement of instrumentation to either infer the liquid level from the measurement of a related physical property, or directly deliver the liquid level visually using a scaled gauge arrangement. One indirect method of level measurement is often referred to as the bubbler method, so named because it employs a purging gas that continually vents from the bottom of a tube extending into a tank of liquid. Through a simple apparatus, the level of a liquid can be inferred by the amount a back pressure exerted upon the gas flowing through the tube.

Probably the greatest advantage of this method of liquid level measurement is that the liquid does not contact the sensing instrumentation. The only portion of the apparatus in contact with the liquid is a tube immersed into the tank. Basically, a purge gas flows through the immersion tube and may bubble out the immersed end of the tube, which is open to allow the contained liquid to exert a hydrostatic pressure on the purge gas. The back pressure on the gas that is exerted by the liquid contained within the tank will vary directly with the depth of the liquid. The back pressure can be correlated to a liquid level. Further calculations, which would include the tank shape, dimensions, and the liquid density can provide an indication of the volume and mass of the liquid. Here is an illustration of the setup, provided courtesy of Brooks Instrument, globally recognized leader in flow and pressure measurement and control. The illustration is from Brooks' January blog article.

Bubbler Method Tank Level Measurement Apparatus, showing application of some Brooks Instrument devices.

Below are data sheets detailing the components used in the system to control and measure the gas flow, and measure the back pressure on the immersion tube. There are other components needed for a complete system, but they are fairly generic in nature and easily obtainable. Contact a flow and level measurement specialist with your application challenges and work with them to produce effective solutions.

Bubbler Method Liquid Tank Level Measurement Instruments from Miller Energy, Inc.

Low Cost Radar Level Transmitter For Industrial Process Applications

Magnetrol Model R82 Radar Level Transmitter

With its ability to reliably detect tank liquid surface level under conditions that prove challenging to other methods, radar technology generally provides an operational advantage over other non-contact level measurement options. Historically, the cost of radar level transmitters for industrial process control applications has hindered their success as a unit of choice for some installations. Magnetrol has changed that imbalance with their recent introduction of a lower cost radar level transmitter for tough applications.

The Model R82 provides radar performance at a price point comparable to competitive ultrasonic units, but maintains the performance advantage inherent in a radar based device. The unit utilizes pulse burst radar technology at 26 GHz, employing advanced signal processing to filter out false echos produced by a range of in-tank conditions that can produce false readings from ultrasonic units.

The short video below provides a closer look at the R82 and its performance advantages. Technical data sheets and any application assistance you may need is available from product specialists. Share your level measurement and control challenges with them and work toward the best solution.

Yokogawa Users Conference and Exhibition is Coming

Yokogawa is presenting its 2016 Users Conference and Exhibition in Orlando, Florida. The event runs from October 3 through October 6 and will be held at the Renaissance Orlando at SeaWorld hotel. Included in the conference agenda are informative technical sessions, training workshops, panel discussions, hands-on demonstrations, essential application sessions, and daily keynote speakers. The opportunities for networking and learning are truly unique and rewarding for those involved in process automation and control.

There is currently a call for presentations, seeking out those who wish to share their applications and challenges. Learn more about the conference and register at the event website.

Yokogawa Users Conference and Exhibition from Miller Energy, Inc.

Yokogawa Publishes New Collection of Case Studies in Process Automation and Control

Yokogawa, an internationally recognized process automation and control provider, strives for customer satisfaction through operational excellence, bringing long-term success to its customers. Now available are collections of actual cases in which Yokogawa helped leading companies in a variety of industries address specific challenges and achieve their goals. The new e-books were redesigned and subdivided into six sectors including LNG, Oil & Gas, Chemical, Pharmaceutical, and Renewable Energy.

Browse the e-books online for insight into the breadth and depth of Yokogawa's capabilities and their commitment to their customer's success. Depending on your screen size, you may need to scroll down the page to see the e-books at the link. At e-books, you can browse using the online reader, or download them as a PDF file.

Share you process control challenges with a Yokogawa representative and expect the best solutions.

Save Time And Get The Right Product With Yokogawa Automated Selection Tool

Yokogawa Corporation of America, an industry recognized source for innovative process measurement and control products, has made available an easy to use product selection tool for those navigating through the company's extensive product offering. The Product Finder is a great time saver that enables a user to quickly locate product and technical information on Yokogawa process instrumentation products meeting the user's selected criteria.

Let's step through a quick example. You will see how this quick and easy to use tool saves time by navigating quickly to the website pages detailing products meeting your requirements.

The Product Finder is accessible through a number of links throughout Yokogawa's network of representatives. Clicking the link lands you on the start page of the Product Finder. For this example, I am going to search for a flow meter with the following characteristics:

• Mass flow measurement 
• Non-conductive liquid
• Accuracy of 1%
• Flow measurement device must have an integral transmitter
• Tri-clamp connections

Above, I declared my location as United States. The next step, shown below, is to select "Flow" as the measurement parameter. You will see in the drop down menu that there are many measurement elements that can be selected, with Yokogawa products for each.

My selection of "Flow" from the drop down menu returns all of the company's flow measurement devices, of which there are many (this cropped screenshot, shown below, only shows four, but there were many more) . This is where the selector really helps you. Instead of examining several or many different models, the user can focus the search by adding more product characteristics. You can see the list of prompting questions on the left side of the page. Providing additional characteristics by answering the prompting questions will narrow the search results to the show only the products meeting all the criteria specified by the user.

The next image (below) shows all of my sample product attributes entered on the left column. Note that there is now only a single product that matches all of my sample criteria. The whole process took less than two minutes. By clicking on the "View More Details" button below the product image, I gain access to all of the available technical, support, and product data for my selected flow measurement device.

The process instrumentation specialists at Miller Energy are available to provide additional help in meeting your measurement challenges. Combine their product knowledge and expertise with your process know-how for the best solutions.

Vortex Flowmeter Delivers High Performance in Harsh Process Conditions

digitalYEWFLO Vortex Flowmeter
Courtesy Yokogawa

In the process measurement and control field, vortex flowmeters are noted for their ruggedness, versatility, comparatively high accuracy, and absence of moving parts. They are compatible with numerous applications requiring measurement of flow in gases, liquids, and steam. The Yokogawa digitalYEWFLO vortex flowmeter is an accurate and stable device, even in harsh process conditions, and has a highly reliable and robust design that can deliver improvements in plant efficiency and reduced operating costs. It is available in several versions, one of which is multivariable, providing a calculated mass flow rate output.

Operating Principle

When a shedder bar is placed in a flow, Karman vortices are generated on the downstream side of the bar. The Karman vortices are detected by two piezoelectric elements installed in the upper part of the shedder bar. The vortex frequency is proportional to the flow velocity in a specific range of Reynolds numbers. Therefore, flow velocity or flow rate can be determined by measuring vortex frequency.

Noise Reduction

Noise caused by strong piping vibration may affect the accuracy of vortex frequency detection. The two piezoelectric elements in the digital YEWFLO are installed in a configuration that is polarized, so they are not affected by vibration in the flow or vertical directions. The noise of vortex (lift)- direction vibration is reduced by adjusting the outputs of the piezoelectric elements. Combining these features with the Spectral Signal Processing (SSP) function provides optimum and stable measurement.

Share your process measurement challenges with a product application specialist. The sharing of ideas and information will produce the best outcome.

Yokogawa digital YEWFLOW Vortex Flowmeters from Miller Energy, Inc.

Handheld HART Communicator Boosts Field Technician Productivity

Yokogawa YHC5150X

The Yokogawa FieldMate family effectively supports the initial setup, daily maintenance, and troubleshooting for the maximum utilization of intelligent field instruments. FieldMate is a flag ship product of the FieldMate family which is a PC based full functional and full field protocol configuration tool. 

The YHC5150X FieldMate Handheld Communicator is the latest HART® Communicator from Yokogawa. All HART® field devices can be configured, polled, and trimmed utilizing a Windows Embedded CE™ based system for faster processing and greater storage capacity. All options are standard and no subscription is required. The YHC5150X is a full function, DD Direct, HART® Communicator supporting universal, common practice, and device specific commands for commissioning, configuration, and maintenance operations. 

A short listing of some of the more prominent features that make the YHC5150X a powerful universal HART communicator include...

• Reads manufacturers' DDs in their native format without the need for translations 
• HART®-compliant modem communicates with any registered or unregistered HART® Device 
• Features an ergonomic, handheld design 
• Enhanced 4.3" diagonal anti-glare touchscreen with color graphic display (no stylus required) 
• Full QWERTY keyboard for commissioning new transmitters 
• On-Demand Help Menus and teachable device-specific short cuts 
• More than twice the battery capacity of any handheld communicator 
• Manage device information through PC connection 
• Integrated multi-language support

The video below provides additional detail and an overview of the product in action. More information on the HART Communicator, as well as other innovative products to improve productivity and effectiveness, is available from a product specialist.

Optimizing Level Control in Combined Cycle Gas Turbine Plants

Magnetrol® International and Orion Instruments®, both recognized global innovators in level measurement technology, provide optimizing solutions for liquid level control in combined cycle gas turbine plants and other similar applications.

An overall cost analysis can reveal savings in the range of 25% to 35% through the application of the most advantageous level measurement technology. Miller Energy, Inc. has developed a short presentation and discussion regarding recent developments now available in the Magnetrol® Eclipse Line of guided wave radar level instruments.

More detail is provided on the single page document provided below. Reach out to Miller Energy and learn how your operation may benefit from the application of guided wave radar level measurement technology.

Optimizing Level Control - Combined Cycle Gas Turbines from Miller Energy, Inc.

Develop a Thoughtful and Comprehensive Alarm Plan for Process Control Operations

Petrochemical plants are one of many industrial process
control operations to benefit from comprehensive alarm plans

Industrial process control operators and designers have the capability to measure many aspects of machine operation and process performance. Determining the elements to measure, method of measurement, and how to handle and process the derived information can be challenging, but can also impact the security, performance, and safety of an operation. A plan for monitoring, reporting, and responding to abnormal process conditions, if properly developed and executed, can yield real benefits to a process operator. A protocol that is not well conceived may produce a negative operational impact by creating events that unnecessarily draw resources away from productive endeavor. That protocol, or plan, is often referred to as an alarm plan.

There are numerous forces that can influence the development and implementation of an alarm plan. Each operation must incorporate its own set of external regulatory requirements, internal procedures and policies into a complete alarm protocol. Distilling that macro description down to a workable set of procedures and response tasks is where the real work begins. There is, however, a basic framework that can help organize your thinking and focus on what is most important.

• What parameters define the process or operation?
  Produce a schedule of every non-human element that is required to make the process function. This will require drilling down through every machine and material that is part of the operation. Expect the schedule to be extensive, even huge. If it is not, consider that your analysis may not be reaching deep enough. The goal here is to create an overview of what makes the process work and provide a tool for systematically studying the process elements and gleaning possible commonalities or relationships among them. Consider disregarding things that cannot be measured, since that prevents the derivation of data for evaluation. Review the completed schedule and decide which parameters shall be measured and evaluated for proper performance.
• What level of measurement is needed for each monitored parameter?
  An assessment of the needed accuracy, frequency, and resolution for parameter measurement will help define the requirements for instrumentation or other devices used to monitor a particular item. The goal is to make sure the monitoring device is capable of detecting and delivering information of sufficient quality to make decisions.
• Define the limits of acceptability for each monitored parameter.
  Until the endpoint of the process or operation, each step is likely dependent in some way on previous steps. The output of each step becomes the input of the next. While this, in many cases, may be an oversimplification, it is important to consider the relationships between the tasks and operations that comprise the process. Monitored parameters should relate to the successful completion of a process step, though not necessarily be a direct indicator of success. The maintenance of the parameter within certain bounds may be used as an indicator that a component of successful completion was properly attained. Defining limits of acceptability may involve an element of subjectivity and will likely be customized to accommodate the process. Each organization shall evaluate their operation and determine limits based upon intimate process knowledge and experience.
• Define abnormal operation for each monitored parameter.
  Abnormal operation may not necessarily be any value not within what is considered acceptable. Consider abnormal to be the range of values that would be cause for notification of the operator, or even automated or human intervention. Note that the definition of unacceptable or abnormal operation might appropriately include filters or defined relationships with other parameters. An example of a simple filter is a time delay. If the measured variable exceeds the specified limit for 2 seconds, it make not be significant. If the threshold is exceeded for 2 minutes, it may be cause to take action. As with the limits of acceptability, developing the definition of abnormal operation for each parameter will be customized for each process.
• Provide a defined response for every alarm occurrence.
  If it is important to monitor something, then it is likely important to do something when things get out of hand. Human executed alarm response should be concise and uncomplicated, to reduce the probability of error. Automated response should be designed in a manner that provides for functional testing on a regular basis. The scope of the response will be specific for each process, with the level of response depending upon factors determined by the process operators. Response can be as simple as annunciating the condition at a monitoring station, or as dire as shutting down part or all of the process operation.
• Review every alarm event.
  Each alarm event should be logged and reviewed. Consider whether the event detection and response was adequate and beneficial. If the results were less than expected or desired, assess whether changes can be made to provide improved results in the future. The alarm plan is unlikely to be perfect in its first incarnation. Be prepared to reevaluate and make changes to improve performance.

The exercise of developing a comprehensive alarm plan will help to build understanding of process operation for all involved parties. This article is but a brief synopsis of the subject, intended to get the reader on the path of developing a useful alarm plan. Your alarm plan should an extension of process operation decision making, and have a goal of enhancing safety and reducing loss. Contact the process control and combustion specialists at Miller Energy for additional input.

Defending Industrial Control Systems From Cyber Attack

Cybersecurity is now a design element of all industrial
control systems

Industrial control system owners, operators, and other stakeholders should be aware of their exposure to malicious intrusion and attack by individuals or organizations intent on inflicting physical damage, stealing information, or generally wreaking havoc throughout an industrial operation. The risk of intrusion, regardless of the size or type of facility, is real and deserves the focused attention everyone involved in the design and operation of industrial control systems.

The National Cybersecurity and Communications Integration Center, part of the US Department of Homeland Security, ...

serves as a central location where a diverse set of partners involved in cybersecurity and communications protection coordinate and synchronize their efforts. NCCIC's partners include other government agencies, the private sector, and international entities. Working closely with its partners, NCCIC analyzes cybersecurity and communications information, shares timely and actionable information, and coordinates response, mitigation and recovery efforts. (from www.us-cert.gov/nccic)

The NCCIC has published a set of seven basic steps toward establishing a more secure industrial control system. I have included the publication below, and it is interesting and useful reading for all involved in industrial process control.

Having a fence around an industrial site, with a guarded entry gate, no longer provides the level of security needed for any industrial operation. Read the seven steps. Take other actions to build your knowledge and understanding of the risks and vulnerabilities. Cybersecurity is now another layer of design tenets and procedures that must be added to every control system. It will be a part of your company's best practices and success, now and in the future.

There are uncountable legacy controllers and communications devices throughout industrial America. All need to be reassessed for their vulnerability in the current and upcoming security environment. When reviewing your processes and equipment, do not hesitate to contact Miller Energy for assistance in your evaluation of our products.

NCCIC - Seven Steps for Achieving Cybersecurity for Industrial Control Systems from Miller Energy, Inc.