Focus Flow & level
Tightening up flow accuracy T
Advances in flow and density measurement technology have delivered outstanding results in chemical process applications, says Steve Smith, business manager Micro Motion, Emerson Process Management
he issues facing process, instrumentation and electrical engineers affect virtually all industrial and process sectors. For the chemical industry, challenges range from handling production com- plexities to preparing for a younger, less experienced workforce. Many of the operational issues faced by engineers in the chemical industry can be minimised by applying best-in- class measurement technologies that provide the needed control coupled with accuracy and actual process insight. Workforce issues require train- ing and knowledge-sharing resources from other experts in the field.
Production changes
Many large, global organisations within the hydrocarbon industry are either amalgamating plants or shifting production to world areas and regions with less expensive feedstock or to be closer to end customers. The result has been the creation of much larger refin- ing and chemical complexes with production capacities far greater than existing plants.
In the past, fine chemical companies manufactured a relatively small range, set their plant up for long production runs and stored the products ready to fulfil their customer orders. Many of these companies now offer a much larger range of formulations and oper- ate their plants on just-in-time (JIT) manufacturing principles. For one manufacturer, this has meant a rise in the number of recipes from eight to 55 and a reduction in the average batch time from weeks to hours.
As a result of these issues, chemical processes are requiring larger, more reliable instrumentation that can handle challenging process flows and a far greater range of flow rates than were previously seen. Processes are being subjected to more two-phase flow and empty-full-empty conditions as manufacturing lines are set up and blown out, ready for each new formu- lation batch. Coriolis meters are now available for large 200-300 mm line sizes, delivering supreme accuracy for these large chemical complexes. To handle difficult operating condi- tions, only Micro Motion meters offer advanced electronics such as multi- variable-digital (MVD) technology that
Process & Control AUGUST 2011
enables faster performance and improved measurement accuracy under difficult process conditions.
Process insight and control In order to cope with the need for more production, engineers are look- ing for ways to tune-up and/or upgrade their processes in order to get greater yield and reduce unplanned process shutdowns. Likewise, greater device diagnostics to be able to predict and prevent unplanned outages as well as extending the runtime between shutdowns, is a requirement to keep these processes up and running. To achieve this, the chemical indus- try often looks for higher accuracy from their measurement and control, which has led to a far greater use of Coriolis measurement technology. Emerson's Micro Motion device diagnostics include Smart Meter Verification. At the touch of a button or on a pre-determined schedule, this can verify the entire Coriolis meter performance (from electronics through to the sensor) while the process is run- ning and in less than two minutes. This feature extends the frequency or eliminates the need for calibration and enables operators to run the plant for longer intervals. Emerson's Smart Wireless THUM adapter is also avail- able to access diagnostics and then transmit the data over a wireless net- work based on the IEC 62591 standard. Another issue for the fine chemicals industry is managing product give
Micro Motion D series Tefzel coated meters installed on a hydrofluoric acid line
away. To avoid not providing the mini- mum specified contents of a product, suppliers will overfill containers. With less accurate measurement devices, manufacturers work to a large margin of error and give more product away. With tight margins and some- times costly ingredients, this means the difference between profit and loss. Manufacturers are looking to tighten up measurement accuracy with high-speed Coriolis mass flow filling measurement technologies.
Raw material quality
Much of the crude oil now being processed and used in the hydro- carbon industry has more challenging properties from oil extracted from older fields such as heavier and sourer crude oil. In addition, to maximise production and profitability, chemical plants are trying to get far more end product from the raw material avail- able. Flow and density measurement meters are now subjected to more extreme conditions such as higher temperatures and pressures. Coriolis meters are now being used that offer a robust and accurate solu- tion for these tough conditions. In addition to handling the high tempera- ture and pressure requirements, meters are available in more exotic materials such as Super Duplex steel.
Changing workforce
For many years, there has been a lack of engineers coming into the process industries. As the long-time engineers retire and their expertise leaves the organisation, many chemical plants are realising that the systems are not in place to capture their knowledge. This has led to a greater reliance on equip- ment suppliers to provide in-depth training and ongoing support. Emerson aims to make products that are not only reliable, compatible and cost-effective but also bring about sig- nificant improvement in ease-of-use and workforce productivity. Its Micro Motion Online Community strives to deliver expertise online while con- necting engineers with their peers to share insights, best practice and flow measurement knowledge. Emerson Process Management T: 0870 240 1978
Enter 212
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