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OIL & GAS – Refinery automation

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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

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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.

Contact us for more information

High-speed level measurement

High-speed level measurement

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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.

Contact us for more information

UWT’s Rotary Paddle switch for point level measurement

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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.

CHEMICAL SAVINGS DURING CIP

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CIP-cleaning in the food processing industry

CIP-cleaning facilities are primarily used in those installations wherever supreme necessities are demanded for hygiene and product safety, such as dairies, breweries and in food production. Throughout this process the complete production facility, including tanks and conducts, are purged and rinsed with cleaning agents and water in several cycles.  The aim of Cleaning-in-Place (CIP) is to remove product residues and microorganisms from all wetted surfaces inside tanks, pipework and filling machines while not disassembling the plant. To warrant optimum and economical cleaning, all parts in direct contact with the product must be made according to the principles of hygienic design.  Anderson-Negele’s motto “Hygienic by Design” is an expression of commitment that sensors fulfill this superior demand of the food processing industry in an exemplary manner.

Sequences of a CIP-cleaning within the example of a dairy

The CIP cleaning process takes place in several coordinated process steps. In the first step remains of the product in the installation are extruded and adhering particles removed in the pre-rinsing process. In the next steps, organic traces are eliminated with caustic and mineral deposits by use of acid. Subsequently, the facility is rinsed with fresh water and thus prepared for the next production step.

  1. Pre-rinsing (water)
  2. Cleaning (caustic)
  3. Mid-cycle rinse (water)
  4. Cleaning (acid)
  5. Rinsing (freshwater)

 

Optimization of the CIP Process

A CIP cleaning process in commonplace applications lasts between 60 and 90 minutes. The operator of a production facility consequently suffers from downtime in production capacity leading to a loss of products, and from increased cost for the consumption of water, energy and chemicals.

The hygienic design of the complete production facility and automatized processes are key factors for a reduction of the cleaning cycle times and for an increase in the efficiency and productivity of the process itself. Being an experienced specialist for sensor technology in hygienic environments, the sensors and process connections from Anderson-Negele are perfectly adapted to the requirements of the food industry and ensure the safe and economical cleaning of the facility and installations.

Why Morton Controls together with Anderson-Negele’s ILM-4 could help you

 The analysis of the return media is one of the most important steps for an environmentally friendly and cost-efficient process. The ILM-4 inductive conductivity meter plays a central role in precisely determining the phase separation: during the discharge of the liquids at each cleaning stage the media are differentiated with cost-saving accuracy.  Re-usable cleaning agent that flows off after cleaning can thus be returned to the tank to the maximum possible degree. In a separate, internal circulation and for permanent optimum cleaning result, its concentration is adapted to the specified ideal value by re-dosing with detergent and fresh water in the cleaning agent tank. The ILM-4 conductivity meter also ensures the highly precise measurement of conductivity and temperature required here.

Inductive Conductivity Meter ILM-4

The ILM-4 is designed for hygienic applications in food-, beverage- and pharmaceutical industries and controlling of CIP processes (e. g. phase separation detergents/water). The ILM-4 is currently equipped with the IO-Link in parallel.  IO-Link offers important benefits over analog technology when it comes to reliably controlling the entire process technology with a variety of measuring points, control and operating elements.

FEATURES/ADVANTAGES

  • CIP/SIP cleaning up to 150 °C/maximum 60 minutes
  • Wear-free, inductive measurement
  • In contrast to conductive measurement procedures, no problems with electrode deterioration or polarization.
  • Accurate measurement through compensation of temperature influences.
  • High reproducibility of ≤ 1 % of the measurement value.
  • Analog outputs for conductivity and temperature are a standard feature.

    Anderson-Negele’s ILM-4 with IO-Link

  • Analog outputs for conductivity, temperature or concentration are freely adjustable.
  • Rapid temperature response time T90 15…60 s
  • Installation in tube diameters from DN 40

 

For more information please contact the Morton Controls team:  0861 000 393, sales@mortoncontrols.co.za, www.mortoncontrols.co.za

 

Anderson-Negele’s NCS-M Capacitive Level Sensor with the MPI-300 programming adapter

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In combination with theMPI-300 USB programming adapter, the NCS-M sensor can be individually adapted to the application used by the customer. In addition to setting the device to the appropriate medium, switching threshold, hysteresis and time delay can also be individually configured.

 

Application examples of the capacitive level sensor:

  • Limit detection in vessels or pipes
  • Product monitoring in pipes
  • Pump/dry running protection
  • Detection of syrup and fruit concentrate

 

 

 

 MPI-300 USB programming adapter in combination with the NCS-M sensor

  1. NCS-M-12:
  • Version with enhanced measurement range for critical media (e.g. Oil, Fat)
  • No adjustment necessary
  • The switching threshold, hysteresis and time delay parameters can be set for the sensor for complex applications
  • Insensitive to foam and adherence
  • Very short response time (< 100 ms)
  • IP 69K

2. The MPI-300:

Adapter for the universal programming of the NCS-M capacitive level sensor family. Level detection even for media with a low or no water content such as syrup, fruit concentrate, alcohols and oils with a dielectric constant εr (Dk) ≥ 2.

The switching threshold, hysteresis and time delay parameters can be set for the sensor.

Anderson Negele’s ILM-4 conductivity sensor with IO-Link

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Conductivity sensor with IO-Link

The ILM-4 conductivity sensor with IO-Link is a big step to industry 4.0 in hygienic process technology.

Proven industry standard now also for hygienic and aseptic applications

IO-Link offers advantages in process control and monitoring. The ILM-4 conductivity sensor, the first of a whole range of measuring instruments to be equipped with an additional IO-Link interface, is a well-known and proven conductivity sensor on the market. This will be followed in due course by the sensors ITM-51 for turbidity, NSL-F for level, L3 for pressure and D3 for differential pressure and volume, all based on the modular platform with fail-safe plug-and-play technology with standard cable for time-and-cost-saving installation and set-up.

The (R)evolution of conductivity measurement

IO-Link offers significant advantages over analogue technology when it comes to reliably controlling the entire process technology with many measuring points, control and operating elements. Set-up and installation are easy and cost-effective. A three-pole standard cable is sufficient for the signal transmission and power supply itself. In practice, point-to-point connections are made at field level from various sensors to collection points, so-called IO-Link masters, and from there via Fieldbus system to the control centre.

 

Simple data transfer becomes intelligent communication

With IO-Link, data streams in the opposite direction towards the sensors are now also possible. In this way, the status of the sensor can be checked and specifically queried at any time. This makes it possible to detect potential faults, signs of wear or an increased risk of failure at an early stage and helps to avoid production downtimes.

“Plug-and-play” takes on a whole new meaning

Sensor replacement of the ILM-4 with IO-Link becomes easier and safer than ever before and can be carried out independently, at any time and by any employee without any programming effort. The device configuration of each connected sensor can be stored in the IO-Link Master. Immediately when plugged in, the new sensor is automatically recognized, configured and parameterized by the IO-Link Master.

The new dimension in hygienic measuring technology is digital and analogue, compact or remote. It is: modular

ILM-4 conductivity transmitter with IO-Link creates planning security and flexibility for status control and sensor diagnostics for preventative maintenance avoids production downtime.  The combination with the modular platform, with the separation of sensor and electronic unit in the optional remote version, creates a unique constellation of hardware and software that is unparalleled in flexibility, simplicity and system compatibility.

ANDERSON-NEGELE’S NEW P41 PRESSURE SENSOR

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Morton Controls introduces Anderson-Negele’s new P41 pressure sensor with temperature compensation providing a quality, robust and cost-effective pressure and level measurement solution.

Pressure sensors for levAnderson-Negele P41 Pressure Sensor el measurement

Anderson-Negele’s new P41 pressure sensor compliments the range of pressure sensors from Anderson-Negele being the D3, L3, LAR, DAN-HH, PFS and P41. With our comprehensive range of sensors based on various measuring methods, you can be assured of a measuring instrument, for process pressure and level measurement, that is precisely tailored to your application.

Robust, needs-based, cost-effective

Despite its compact appearance, Anderson-Negele’s new P41 pressure sensor is designed to meet the high demand of process requirements: Pressure up to 40 bar, overpressure resistant up to 100 bar, vacuum resistant. The measuring range can be individually adapted to the desired process pressures and a choice can be made between absolute and relative measuring cells. Compound measurement is also possible, that means that the relative measuring cell can also be used to measure the vacuum range.

The P41 is robust when it comes to temperatures: up to 125 °C as standard, up to 150 °C / 60 min for CIP/SIP cleaning, and even up to 250 °C permanently with optional cooling section. The entire sensor, including the diaphragm, is made of stainless steel for excellent cleanability and durability. The P41 is versatile in terms of process connections and offers, in addition to the hygienic thread “G1” with CLEANadapt, further connections according to DIN 3852 in “G1/2” and “G1”, as well as Tri-Clamp and Varivent.

The complete rugged process sensor system from a single source

Morton Controls in conjunction with Anderson-Negele offer an extensive range of sensors to make all fluid processing application efficient and reliable.  With temperature, pressure, filling level, limit level, flow measurement and monitoring along with conductivity and turbidity. Measuring methods are adapted to the special requirements for the demands of process industry, due to their innovative products that are specifically designed for sanitary and hygienic sensitive areas. Solutions based and customer-oriented approach, Anderson-Negele has become synonymous with quality and efficiency in the food, beverage and life sciences industries.

We are pleased to bring Anderson-Negele’s new P41 pressure sensor to our clients.

Contact us today if you would like to find out more.

 

PETROCHEMISTRY: CHLORINE-ALKALI ELECTROLYSIS

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PETROCHEMISTRY 

 CHLORINE-ALKALI ELECTROLYSIS

The chlorine-alkali electrolysis is an important procedure in the chemical industry. The products chlorine, hydrogen, hydrochloric acid and caustic soda are generated from sodium chloride. There are three manufacturing methods: the diaphragm, the membrane and the amalgam process.

The LiquiSonic® analyzer provides an advantageous utilization in the varied process steps of the three methods. Foremost, the customer gains the advantages of a reduction in raw material and energy consumption, as well as an increase in the yield.

 

LiquiSonic® measuring points in the processes of the diaphragm method of the chlorine-alkali electrolysis

 

Preparation of end products

1.1  Caustic soda concentration

The market ready caustic soda (NaOH) typically has a concentration between 45 wt% and 50 wt%. Since NaOH gained from electrolyzer cells only yields a concentration range between 12 wt% and 33 wt%, it is concentrated in cascade evaporators.

If together with NaOH the solution contains NaCl (diaphragm method), the excess salt in the caustic soda precipitates in a crystal form during the evaporation. This way, the NaOH-concentration is elevated to 45 wt% and 50 wt%.

The LiquiSonic® analyzer continuously determines the concentration of caustic soda at any time after evaporation. A subsequent dilution of the caustic soda to a customer specific product concentration, can also be monitored.

ADVANTAGES:

  • Continuous concentration monitoring of the caustic soda
  • Reduction in the energy costs during the evaporation process

1.2 Chlorine gas drying

Water content needs to be removed from the chlorine gas before it is further processed as its corrosives elevate at a moisture content of over 30 ppm. For the drying, the chlorine gas is routed into the absorption towers, where the water content in the chlorine gas is absorbed with highly concentrated sulfuric acid (80 – 99 wt% H2SO4).

The effectiveness of this drying process significantly influences the productivity and quality of the gas. Therefore, a reliable measurement of the H2SO4 concentration is vital. The LiquiSonic® analyzer offers a continuous and safe monitoring of the H2SO4-concentration, in opposition to conductivity and density measurement.

ADVANTAGES:

  • Elimination of labour intensive sampling
  • Continuous monitoring of H2SO4-concentration
  • Clear concentration determination signal between 80 wt% and 100 wt% H2SO4
  • Ensuring the desired Cl2 dryness to avoid corrosion in the system

1.3  Hydrochloric acid production

The chlorine gas that is generated on the anode of the electrolyzer with the added hydrogen form the base materials for the synthesis of hydrochloric acid. Both gases are fed into a burner and react to form hydrogen chloride. Subsequently, the formed HCI-gas streams from the burning chamber into the integrated isothermic falling-film-absorber. Here, the gas is absorbed with the help of water or diluted acid, whereby concentrated hydrochloric acid (37 wt% HCI) is formed.

Using the LiquiSonic® analyzer, a continuous monitoring of the hydrochloric acid concentration is possible. This allows for deviations to be recognized from the target concentration and to react accordingly.

ADVANTAGES:

  • Continuous concentration monitoring of hydrochloric acid (20-40 wt% HCl)
  • Ensuring an extremely precise target concentration

Advantage of sonic velocity as compared to conductivity and density

 

 

suspended solid sensors

SUSPENDED SOLID SENSORS – GET BETTER CONTROL

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For better control over your suspended solids, we recommend Quadbeam’s S-range of suspended solid sensors, both for hygienic and immersion capabilities.

In addition, you will realise cost savings, a reduction in losses, and higher concentration control, in a repeated and accurate manner.

 

THE MAIN FEATURES OF THE S-RANGE SUSPENDED SOLID SENSORS

  1. Because of the 4-beam self-compensating sensor, drifting is eliminated and therefore electronics aging and contamination is done away with
  2. You have one-piece piece casing and therefore no leakage in the lenses – completely glass-free
  3. These sensors are reliable, repeatable and accurate

Quadbeam offers a number of models in their suspended solid sensors, namely:

Under Hygienic –

– S10-3HY

– S10HT-3HY

– S10-2HY

– S20-3HY

– S40-3HY

And, under Immersion:

– S10-IMM

– S20 -IMM

– S40-IMM

And, under Variline:

– S20-VN

– S40-VN

 

The measurement range of the S-range sensors are impressive:

– 0 – 25g/L in normal activated sludge (immersion)

– 0 – 40% milk fat (hygienic)

All dependent on the media and particle size

 

THE VARIOUS APPLICATIONS:

Quadbeam’s S range covers a wide area of applications, namely, mining, waste water, pulp and paper, dairy, and food and beverage.

For industrial applications, they are able to deal with the activated sludge measurement for return and waste. In the food, beverage and dairy arena, the monitoring of high levels of suspended solids is a popular application.

 

For hygienic applications:

– the product to water interface

– monitoring on fruit pulp

– concentration control of solids

– concentration of milk fat

 

For immersion applications:

– digested and thickened sludge to clarifiers

– measurements of waste and return sludge

– filter, gravity and centrifugal

 

Should you be wanting to explore these range of sensors, we urge you to make contact with us and we will arrange a demo at your convenience.