OIL & GAS – Refinery automation

PHASE SEPARATION

SensoTech’s LiquiSonic® is an inline analytical system for determining the concentration in liquids directly in the running process without delay. The device is based on meticulous measurement of the absolute sonic velocity and process temperature allowing for the detection of phase transitions.

 Phase separation in pipelines

The accurate detection of various phases in a pipeline is necessary for several industries. Often multiple products flow through the same pipe, but every single product is supposed to end in a different location. In applications in which product A is discharged by product B, the intermediate phase is to be separated.

Safety aspects are closely connected in applications with high-risk potential. In particular, the monitoring in multi-fuel pipelines for the petrochemical industry provides not only data about the product quality (incoming goods), but also avoids incorrect filling of storage tanks and thus serious accidents.

In the petrochemical industry, contrasting fuels are conveyed over long distances in just a pipeline. Here the rapid detection of the different products as well as the quality monitoring is focused.

 Phase separation in batch processes

In batch processes, the product phases are separated due to the physical and chemical properties of each product.

Application example: biodiesel/glycerol

In the manufacture of biodiesel, glycerol is produced as a by-product. The mixture of the two substances is conveyed in large settling tanks and then has several hours to separate. The LiquiSonic® sensors are usually installed into the outlet of the tank. By the detection of the phase transitions, the valve is activated and the biodiesel and the glycerol are supplied to the processing. The intermediate phase returns to the separation process.

 Phase separation in continuous processes

In a continuous process, one or more sensors control the separation of a process stream. In this instance, only the phase-specific value of sonic velocity is monitored and kept constant.

Frequently, the product concentration of the carrier phase varies in the inlet. This quickly shifts the height of the phase boundary. Thus, the carrier phase could be pulled off with the product, which greatly affects the purity. In process the separation is made via one pump in each of the two outlet pipes.

The advantages of the LiquiSonic® measuring and analyzing technology are both the rapid response time of less than 1 s and the connection of up to four sensors to only one LiquiSonic® controller. The controller processes all measuring values and passes the data to the process control system. Depending on the type of vessel and process objectives different installation

variants are possible.

Outlet valve (BOV) with integrated LiquiSonic® sensor

Hygienic limit switches for processes

Hygienic limit switches for processes

Hygienic limit switches for processes

February 2020 Maintenance, Test & Measurement, Calibration

Hygienic limit switches for processes

Process and storage vessels incorporate Hygienic limit switches to prevent overfilling of a tank or vessel (full indicator) or dry running of a pump (empty indicator). Anderson-Negele’s NCS series are ideally suited for the reliable measurement of limits in media with low water content, such as certain alcohols and cosmetics, providing universal application in bottling and pharmaceutical applications.

Capacitive working principle

Anderson-Negele level switches operate on the basis of the capacitive working principle. The measuring electrode, the medium and the conductive wall of the tank form an electrical capacitor influenced by three main factors: distance; area of the electrode surfaces; and type of medium between the electrodes.

The measuring electrode and the tank wall serve as the capacitor plates while the medium acts as the dielectric fluid. Due to the higher dielectric constant of the medium relative to air, the capacity increases when the electrode is immersed in the medium. Exposing the electrode has the opposite effect. The change in capacity is analysed by the level switch and converted to a corresponding switching command. The sensor outputs a 24 V DC signal (active output). The minimum and maximum (full/empty) switching functions can be swapped by reversing the polarity of the power supply. The capacitive working principle requires that the sensor tip, which is made of PEEK, be completely immersed in the medium. The advantage is that the sensor does not respond to foam or adherences and a signal is emitted only when the medium reaches the level. Capacitive measurement is most reliable when the dielectric conductivity and temperature of the medium are constant. Changes in the outer conditions are generally non-critical in media with high dielectric constant values.

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Rotary paddle switch with rope extension for point level measurement in silos

Rotary paddle switch – Level Measurement & Control

Rotary paddle switch with rope extension for point level measurement in silos

February 2020 Level Measurement & Control

A motor-driven shaft causes the vane to rotate. Once the material level reaches the vane, thereby preventing further rotation, this creates a torque, which is converted via a switch to an electric signal. Once the vane is free again of the material, the output signal is reset, and the motor-driven shaft rotates again. This dependable and maintenance-free limit switch for safe level detection in bulk solids has international approvals for use in gas and dust hazardous areas and is also certified to SIL

The RotoNivo offers a universal voltage power supply, 24 V DC to 220 V AC. It can be connected to the same unit without any alterations being made and with the absence of additional power supply to the unit, for example, in very old plants, is completely nullified. This makes it easy for a processing plant to keep one version in stock that can be used in various applications on different parts of the plant. UWT suits the unit to your application, to ensure complete reliability and effectiveness.

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High-speed level measurement

High-speed level measurement

High-speed level measurement

February 2020 Level Measurement & Control

Morton Controls in partnership with Anderson-Negele has introduced the innovative NSL-F High-speed level measurement sensor based on a modular device platform. The new platform strategy used with this sensor is based on a building-block principle that offers great flexibility in the assembly of individual sensor components.

Users benefit from the advantages of the system and profit from the reliability with which these sensors provide measurements, even in strongly adhesive and foaming media. For example, the device will accurately display that a tank is empty even in the presence of substantial foam. Due to the short response time, highly accurate metering processes can be reliably realised with the NSL-F – even with alternating and pasty media.

Anderson Negele’s specific Flex-Hybrid technology allows for easy operation of the sensor with either digital IO-Link or analog 4-20 mA technology, as well as in parallel with both interfaces. Other features include:

• Status control and sensor diagnosis for preventive maintenance and avoidance of production downtime.

• Interference-free plug-and-play technology with standard cable for time and cost-saving installation and commissioning.

• Uniform configuration for all sensors without the need for company-specific programming adaptors.

• Easy sensor replacement: automatic detection, configuration and parameterisation when plugged in.

Applications include continuous level monitoring in metallic vessels up to 3 m in height, level monitoring in feed vessels suited for adhesive and pasty media, level measurement in storage tanks of foaming media, and content measurement in pressurised vessels.

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Content measurement in Silos and storage hoppers remastered

UWT has taken the old-time rock ‘n roll method of content measurement in Silos and storage hoppers and remastered it to perfection, enabling seamless integration with our modern-day control systems and PLC’s. The UWT NivoBob continuous level measurement system offers a high-tech Approach version of a simple and very reliable measurement principal:

The basic working principle is as follows:

  • Sensor weight drives down on a measuring rope/ tape.
  • The rope/ tape length is electronically measured by the rotation of the internal rope/ tape roller
  • Material contact stops movement and the rope/ tape relieve for a short time
  • Motor changes the direction of rotation
  • Sensor weight is driven back to the upper stop position
  • The distance is measured, and signal outputs are activated (pulse/ relays/ 4-20mA/ Modbus/ Profibus)

APPLICATION EXAMPLE:

THE CHALLENGE:  Content measurement for silos – The level measurement should be carried out in storage silos for gypsum powder. The finished product is conveyed pneumatically into the storage silo after production. The overall production planning is difficult if the fill level monitoring of the storage silos is missing. The operator previously had to climb onto the silo roof and carry out a manual level measurement with a rope and a weight. This yielded inaccurate results and caused huge losses in stock management and control. The task was to automate the level measurement and to avoid manual measurements.

THE SOLUTION:  The UWT lot system Nivobob 3200 in the tape version fulfills these extreme requirements. The integrated tape cleaner prevents contamination of the band interior. The Nivobob 3200, thereby, provides a reliable measurement that can be totally trusted. Neither very dusty nor clumpy conditions adversely affect the UWT Lot system. The electromechanical sensor NB3200 is developed for dusty applications and for high process temperatures and is the best solution in this gypsum storage.

THE PRODUCT:  NB 3200 Tape Version

Nivobob NB3200

Nivobob NB3200 belt and stinger front

FEATURES OF THE NB 3000 SERIES:

  • No adjustment to media necessary
  • Discontinuous level measurement for nearly all kinds of bulk solids
  • Solids in liquid interface measurement
  • Insensitive to dust, dielectric constant, conductivity, humidity, caking, changing product characteristics
  • Easy installation & maintenance-free
  • Corrosion-resistant due to high-quality coatings and stainless steel
  • Very precise results covering large measuring ranges up to 50 m under difficult conditions
  • Separated chambers (mechanic/electronic)
  • Integrated tape cleaner for difficult bulk materials (powder, build-up) to save the mechanic chamber
  • Modus and Profibus Interface with 4-20mA and relay inputs and outputs.
  • Process temperature up to + 250 C possible
  • Process overpressure -0,5… + 1,7 bar
  • Suitable for hazardous locations (dust explosion ATEX II 1/2D)
  • Process connection thread R 1 ½ “, flange DN100 PN16 or others
  • Various measuring weights available depending on application conditions
  • Measuring interval 30 minutes 24 H a day – motor lifetime: 28.5 years

When it comes to ignoring the cone after filling or the upside-down pyramid after draining the silo/ bunker, and achieving reliable, accurate measurement results, Physics and experience play a role. To get to this, the NivoBob must be mounted 1/3rd from the radius of the silo to accurately cancel out the cone effect you will get.

 

Reliable empty alarm in cosmetics tank

Reliable empty alarm in cosmetics tank

Economy and ecology in harmony through automatic monitoring of the filling line – Reliable empty alarm in cosmetics tank with NCS-L-12/18   

For over 60 years, the French brand Yves Rocher has been synonymous with high-quality cosmetics based on vegetable raw materials. The company is strongly committed to ecological issues and biodiversity. Even small factors such as the optimal use of raw materials play a role.

  1. The application

The filling systems for cosmetic creams were previously controlled manually. The filling level in the buffer tank had to be monitored by an employee and the filling process had to be stopped manually at the appropriate moment.

In order to prevent the filling pump from running dry, the process was stopped for safety reasons at an early stage, leaving important quantities of cream in the tank. This residual product was then disposed of, resulting in a significant loss of value.

Application advantages

  • Significantly lower product losses due to optimal emptying of the tank during filling
  • Precise measurement results despite high viscosity of the cream and corresponding adherences to the sensor probe
  • No manual control and monitoring required
  • Fast amortization through reduction of product losses and time savings for employees
  1. The solution

With the NCS-L level sensor, the filling process is automated. Due to its special sensor shape with 18 mm length and its measuring method with an extended measuring range, the NCS-L-12/18 is particularly suitable for low-water, viscous media such as oils, syrups or even cosmetic creams. Due to its inline integration in the outlet pipe of the filling system, the sensor signals safely and reliably as soon as the cream is depleted, thus stopping the filling process automatically.

  1. The result
  • Cream losses are minimized.
  • The quantities of waste to be disposed of (cream remaining in the tank) is reduced.
  • Impurities (splashes due to dry running of the filling pump) are avoided.
  • Maximum process reliability for the personnel operating the filling system
  1. Sensors used in the application

NCS-L-12/18                   NCS-01, NCS-M, NCS-L-31P

       4.1 Point level NCS-L-12/18

 Advantages:

  • Limit level detection even with media with low water content such as syrup, fruit concentrates, alcohols and oils with εr (Dk) ≥ 2
  • Reliable indication even with strongly adhesive media due to capacitive measuring principle
  • Very short response time

4.2 NCS-01, NCS-M, NCS-L-31P

Advantages:

  • Insensitive to foam and adhesions
  • Different sensor lengths for adaptation to all installation situations in pipes and vessels

 

 

 

 

Tailor-made solutions for the textile industry – UWT solution in acetone

 

Tailor-made solutions for the textile industry – UWT solution in acetone

Single-rod probes using the capacitive measuring method are in many cases a clever solution when it comes to level detection. They can be found in overfill protection and as demand or empty detectors in process or storage containers. These limit switches are suitable for almost all bulk materials from different industries, due to high sensitivity, high mechanical load and a variety of probe extensions. But these qualities also make them a suitable solution in the fascinating world of varied liquid applications, be they in food, wood, rubber, plastics, environmental and power plants, building materials, and chemical industries.

Tailor-made solutions - UWT solution in acetone

Capacitive sensor RFnivo® RF8100 for point level measurement

The use of the RFnivo® capacitive rod within the textile production process featuring the aggressive substance of acetone.

Satisfied by a classic solution – The Rotary Paddle Level Switch

A synthetic fibre company producing a wide range of polyester textile yarns, geotextiles and carbon, and heat resistant polypropylene materials, for products such as special protective clothing or packaging solutions in agriculture and construction have successfully installed Rotonivo® devices for different powders and granules in several process vessels. Depending on the requirements, they function as full, demand or empty detectors and, thanks to their simple electromechanical measuring principle, can also be adapted to extreme process conditions, such as high temperatures up to +1,100°C. The RN rotary paddle is mainly used for storage and drying of plastic particles as a full detector as well as in dosing tanks and extruders for demand reporting. During conveying processes, it works as an overfill detector. For protection against temperatures of below -20°C, a heating function was integrated in the electronics.

Level measurement in clean and contaminated acetone within the textile industry: Capacitance solution in acetone tanks for overfill protection and empty detection

As the synthetic fibre manufacturer was satisfied with the rotary paddle detectors, they also required a measuring solution from UWT for their acetone containers.  Preliminary tests in the solvent tanks were conducted.  During synthetic fibre manufacturing, acetone is used to impregnate the fabric. Each fabric to be produced is passed through a bath of clean, pure acetone, where amongst others excess epoxy resin, which is used for bonding the fibres, is washed off. Most of the resin is usually cured after the heat treatment, non-hardened epoxy resin can be removed during this process step. Thereafter, the acetone is considered polluted and enters a separate tank, where it is cleaned in a special mechanical process. Subsequently, the purified solvent is filled in the tank container with so-called regenerated acetone.

Acetone is an extremely aggressive substance that secretes corrosive vapors and quickly corrodes ordinary materials. For the individual tanks with clean, contaminated as well as regenerated acetone the synthetic fibre manufacturer needed a reliable, and at the same time robust, level monitoring system. Tests carried out with a variety of sensors made it clear that the robust RFnivo® probe was the most favorable solution. The RF series consists of single-rod probes that require, due to their design, no temperature-limiting components for media detection and can, therefore, be used in processes of up to 500°C.

They work with the capacitive measuring principle, whereby the capacitance is detected independently of the length of the sensor of the medium between the probe and the container wall.

 

The customer has different tanks measuring from 1.2 to 1.6 meters in diameter. Apart from a reliable measurement, even with frequently occurring pressure fluctuations, it was also essential that the sensor carried a corresponding certificate according to gas explosion protection (Zone1). Firstly, each tank was equipped with an RF probe (standard version) for full signal, that ensured reliable protection against the overfilling of the acetone containers. Secondly, an empty detection system was installed in each container, that switches on time to prevent dry running. As it is common that the sensor probe is exposed to the acetone and the aggressive molecules of the acetone vapour for longer periods of time, especially during the empty detection process – it was realized that an extra robust version of the device was required. The capacitive single rod was thus refined – 1.4404 (316L) stainless steel and PPS isolators were used with a FFKM seal in the product-contacting probe.

The FFKM seal (perfluoroelastomer / perfluoro rubber) has a particularly high chemical resistance against aggressive materials. Perfluoro rubber is considered as the new generation plastic. It is a true high-tech elastomer, which is always used when special demands are placed on resistance to chemicals, temperature, and form. The equipping of the probe seals of the capacitance level indicator with the highly robust polymer made them resistant to the acetone. Clean and regenerated as well as contaminated acetone tanks can be similarly monitored using the capacitive measuring principle.

The Active Shield Technology, which is integrated into the RF probe as standard, also ensures that the measurement result will not be affected by any build-up on the sensor probe. A total of 16 acetone tanks could be fitted with a reliable content monitoring, which meant the optimal support of a smooth and maintenance-free manufacturing process for the synthetic fibre producer.

What is important to the operator?

The RFnivo® calibrated itself after mounting and wiring in the box after power was applied. The operator had to do nothing further but set the signal output in the Quickstart menu after application. If a RFnivo® is used in an application to which the supply voltage has already been applied, only the calibration button needs to be pressed after installation in the container. The probe automatically adjusts to the new application. Thus, the calibration of the RFnivo® is easily performed. For “diehard” RF probe operators, there is also a powerful manual and menu-driven calibration. This ultimately leads to the same result as the automatic calibration. The universal voltage electronics are clearly equipped with a display and 3 control buttons and provide a DPDT signal output for signal evaluation. During operation, the display will always show the capacity measured at that moment. Parameters such as FSH (fail save high) and FSL (fail save low) as well as reaction time of the signal output can be clearly arranged in a quick start menu. A test button allows the manual start of a self-diagnosis of the sensor. If required, an automatic self-diagnosis can be set, which then regularly checks the correct function of the RFnivo® and activates the failsafe in case of error. This self-diagnostic runs in the background without affecting the function of the probe in the application. A simple operating system was integrated into the capacitance limit switch, which can be easily operated.

 

UWT’s Rotary Paddle switch for point level measurement

UWT’s Rotary Paddle switch Rotonivo® RN 3002 with rope extension for point level measurement

Limit detection is required in most silos and containers to avoid overfilling or unnecessary downtime. The sensor needs to deal with an assortment of process conditions within a wide range of industries.

Contingent upon the necessities, the Rotonivo® rotary paddle switch is utilized as a full, demand or empty detector in storage silos or process vessels and is suitable for use in almost all solids. With its simple electromechanical measuring principle, it can also be adjusted for extraordinary process conditions.

A motor-driven shaft causes the vane to rotate. Once the material level reaches the vane, thereby preventing further rotation, this creates a torque, which is converted via a switch to an electric signal. Once the vane is free again of the material, the output signal is reset, and the motor-driven shaft rotates again.

This dependable and maintenance-free limit switch for safe level detection in bulk solids has international approvals for use in gas and dust hazardous areas and is also certified to SIL

The RotoNivo offers a universal voltage power supply, 24VDC to 220VAC. It can be connected to the same unit without any alterations being made and with the absence of additional power supply to the unit, for example in very old plants, is completely nullified. This makes it easy for a processing plant to keep one version in stock that can be used in various applications on different parts of the plant.

UWT suits the unit to your application, to ensure complete reliability and effectiveness.

Features:  Suitable for most bulk solids

  • Reliable, easy to operate and maintenance-free measurement principle.
  • Unaffected by dust, electrostatic charging and caking.
  • Compact, rotatable electronics housing for easy installation.
  • Mechanically stable shaft bearing design with ball bearings.
  • Process seal with radial shaft seal.
  • Robust aluminium die-cast housing.
  • International approvals for use in potentially explosive atmospheres (dust)
  • Varying shaft lengths available.
  • Enclosure IP66 as standard.
  • Wide range of process connections and supply voltages available.
  • RoHS compliant.

Anderson-Negele provides application-specific hygienic Sensor solutions

Morton Controls in partnership with  Anderson-Negele provides application-specific hygienic sensor solutions and support for safe processing in the Food & Beverage and Pharmaceutical markets.

TFP-164

TFP-164 Flush Temperature Sensors – Temperature Measurement in vessels and pipes with flush Hygienic process fitting.

APPLICATIONS:

Applications include monitoring of temperature measurement in vessels with agitators and stirrers and in pipes where an inserted probe is not suitable.

FEATURES:

  • Product contacting materials compliant to FDA
  • Sensor completely made of stainless-steel resp. PEEK (front flush sensor)
  • Conforming to 3-A Sanitary Standard 74-06 for front flush sensors
  • Front flush mounting possible
  • Integrated transmitter optional
  • Different electrical connections available

P41


P41 Pressure Sensors – Pressure transmitter device for hygienic pressure monitoring for various applications in breweries, dairies and food & beverage industries.

APPLICATIONS:

Sanitary pressure measurement in pipes and tanks for process temperatures up to 250 °C for ranges from 0.2 to 40bar.

FEATURES:

  • Hygienic process connection with G1/2″ & G1” CLEANadapt
  • Rapid response time of < 10 ms
  • Vacuum-proof
  • Full stainless-steel body & easy installation
  • Electrical connection with M12 plug connection
  • Available with relative or absolute measurement cell
  • Built-in two-conductor measurement converter 4…20 mA

HM-E

HM-E Turbine Flow Sensors – Measurement of flow rate and volume in hygienic applications.

APPLICATIONS:

Designed for hygienic applications in food-, beverage- and pharmaceutical Industries e.g. Process water, demineralized water, aqueous media such as filtered fruit juice or beer, alcohols, light oils, saline solutions, cleaning agents, and acids.

FEATURES:

  • High quality and hygienic alternative to industrial, non-hygienic turbine, paddle wheel or variable area flowmeters
  • Economical alternative to mass flowmeters in non-conductive, low-viscosity media
  • Cost-effective and compact alternative to magnetic-inductive & Coriolis flowmeters
  • Hygienic design, confirmed by 3-A & FDA certification

NCS-M-12

NCS-M-12 Level Sensors – capacitive limit detection in metallic vessels and pipes with hygienic thread G1/2″ (CLEANadapt)

APPLICATIONS:

Limit detection of fluid also with low or no water content like syrup, fruit concentrates, alcohols and oils with a dielectric constant εr (Dk) ≥ 2

FEATURES:

  • Hygienic process connection with CLEANadapt
  • Conforming to 3-A Sanitary Standard
  • All wetted materials are FDA-conform
  • CIP- / SIP cleaning up to 143 °C / max. 120 minutes
  • Compact installation size
  • Capacitive measuring principle
  • Independent of the medium conductivity
  • Insensitive to foam and adherence
  • Very short response time (< 100 ms)

Save time and money with Quadbeams suspended solids sensor/turbidity meter

Quadbeam Technologies’ Stormwater and Wastewater Sensor, the SWW, is a unique suspended solids sensor/turbidity meter.  The intended use of the S20-SWW and S40-SWW sensors is the continuous monitoring of Suspended Solids concentration in a non-hygienic industrial, stormwater, raw water or wastewater installation.

Quadbeam uses the four beam alternating light ratio-metric system of measurement for its sensors. Suspended Solids Sensors and Turbidity Sensors measure the change in light intensity to produce a relative measure of the solids or turbidity concentration in the liquid being monitored. Other suspended solids sensors and turbidity meters use only a single beam of light. When a single beam of light is used light intensity can be influenced by not only the solids particles suspended in the liquid, but also any solids/contamination that are stuck to the surface of the sensor and variability of the light source and photo diode as they age. It is therefore critical to keep single beam sensors very clean for accurate readings.

Multi-beam sensors measure across multiple light paths allowing them to use mathematical algorithms where the change in ratio of intensity of light is measured. This system automatically compensates for contamination stuck to the surface of the sensor and variation of the light components in the sensor. For this reason, it is common for multi beam sensors to be used in Process Control installations where a repeatable output is very important.

Applications:

The Quadbeam SWW sensors can be used in a wide range of Turbidity and Suspended Solids Monitoring and Control Applications, including;

  • Stormwater Sediment Monitoring and Control
  • Wastewater Suspended Solids Monitoring
  • Flocculant Dosing Control
  • Environment Turbidity Monitoring
  • Raw Water Supply
  • Remote Turbidity Monitoring
  • Irrigation Water Turbidity Monitoring

S40-SWW

S20-SWW