38 Flow Level Pressure
Measurement Technologies Increase Plant Effi ciency and Reduce Costs for CAROM in Romania
CAROM Onesti has improved mass balance, increased boiler effi ciency, and reduced tanker turnaround times at its petrochemical production and distribution facility in Romania. Vortex and Coriolis fl ow measurement technologies from Emerson Process Management (USA) enabled more-accurate and reliable measurements that reduced product loss in the MTBE plant by 150 metric tons per month, improved boiler effi ciency by 3 per cent, and eliminated the need to rework tanker fi lling operations in its distribution terminal. These improvements together have provided savings of €1 million per year.
Mass balance is vital for complex processes within reactors and distillation columns, and achieving that balance requires accurate and reliable fl ow measurement. However, the differential pressure (DP) fl owmeters CAROM used previously required frequent maintenance because process fl uids sometimes polymerised inside the meter − clogging impulse lines and leading to bad measurements.
To solve this problem, CAROM installed Micro Motion Coriolis fl owmeters from Emerson. The new meters’ reliable accuracy enabled the required mass balance to be achieved, reducing product loss by 150 metric tons per month for savings of €700,000 per year. Based on current
production fi gures, this saving translates into a 2 per cent increase in overall plant effi ciency. In addition, because Micro Motion fl owmeters have no moving parts, maintenance costs have been signifi cantly reduced.
Emerson’s measurement technology also helped CAROM improve the performance of nine boilers that provide superheated steam to the site’s production units. Impulse lines for the three orifi ce fl ow meters previously used to measure the fl ow of superheated steam suffered a number of leakage problems, requiring on average around 300 hours of maintenance a year. In addition, the loss of up to two tonnes of steam per hour meant that more fuel was being used to meet the production demands.
“Following the installation of Emerson’s Rosemount 8800D Vortex fl owmeters with integral temperature sensors for each line, the improvements were immediately evident,” said Marian Stancu, chief energy engineer for CAROM Onesti. “Maintenance requirements were reduced to almost nothing, and because steam loss was eliminated, boiler effi ciency improved by 3 per cent, saving more than 200,000 per year in fuel. This meant that our initial investment was recovered in just 25 days of operation.”
Within the fuel distribution terminal, tankers leaving the facility by road or rail are weighed to ensure they have been correctly fi lled. If the fi lling is not accurate, the tankers have to return to the terminal − extending the time and cost for loading. Additional personnel and labour hours are required, and vehicles and locomotives are left standing idle.
“CAROM needed a measurement technology that is suitable for our diesel and petroleum products, and is accurate, reliable and easy to use and install,” continued Stancu. “Having successfully used Emerson’s Micro Motion Coriolis technology for mass measurement in other areas of our plant, we extended the use of this technology to diesel truck loading.”
The Micro Motion fl owmeters improved measurement accuracy and enabled CAROM to optimise truck loading. With a typical train comprising 10 tanks, the loading process that used to take at least two days can now be completed in less than one day. The optimised loading has enabled savings of over €90,000 per year, and the faster train turnaround is also saving over 300 labour hours a year.
“Combining the process knowledge of our local team with Emerson’s product and application knowledge has provided the best solutions to our measurement problems,” added Stancu. “Emerson has become a trusted partner, and its Rosemount and Micro Motion measurement technologies have enabled savings of €1 million per year.”
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Sierra Instruments (USA), global mass fl ow meter manufacturer, is pleased to announce its evolutionary QuadraTherm 640i/780i air fl ow meters haves received global approvals for the following standards of safe operation in potentially hazardous environments: cFMus (USA and Canada), ATEX (European Union) and IECEx (International). This signifi es that the QuadraTherm is certifi ed as fl ame-proof and protected from dust ignition sources and meets all design criteria for electrically-powered fl ow meters used in areas where combustible gases may be present.
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The IECEx and ATEX certifi cation programs ensure explosion-proof and hazardous area compliance in the European Union and international destinations. The cFMus certifi cation program ensures explosion-proof and hazardous area compliance in the United States and Canada. With approvals, QuadraTherm is approved for applications in hazardous plant areas like facilities management, chemical processing, oil & gas, wastewater, and natural gas throughout the European Union and international communities.
“We designed and tested the QuadraTherm air fl ow meter for safe operation in heavy industrial applications. The global approvals are a recognition that years of hard work in design and testing were right on target. Now our customers can use the QuadraTherm in even more heavy industrial application across the globe,” says Scott Rouse, Product Line Director.
The QuadraTherm thermal mass fl ow meter’s approvals are as follows:
cFMus - Class I, Division 1, Groups B,C, and D; Process Temperature Range: -40°C to 200°C (-40°F to 392°F); T3C Ta = -40°C to 60°C (-40°F to 140°F), and Type 4x. ATEX and IECEx Approvals - II 2 G Ex d IIC T3 Gb; II 2 D Ex tb IIIC T200°C Db; Ta = -20°C to 60°C (-4°F to 140°F); Process Temperature Range: -40°C to 200°C (-40°F to 392°F). With these global approvals, Sierra’s QuadraTherm air fl ow meter can be used throughout the world where hazardous or explosive environments may be present, expanding the market for our customers.
The QuadraTherm provides the best accuracy +/- 0.5% of reading above 50% of full scale for fl ow meter air measurement and other gases; built-in fl ow conditioning (inline version); multivariable outputs; fl ow ranges up to 60,000 sfpm (305 smps); qTherm, Dial-A-Gas, Dial-A-Pipe; and Hazardous Area approvals. The QuadraTherm is available in two models: the 640i insertion and 780i inline. The QuadraTherm family has a no-drift sensor with lifetime warranty; has multivariable output: mass fl ow, temperature, pressure (optional); measures all inert and all non-condensing clean gases; fl ammable gases (methane, propane, hydrogen, and digester gas); repeatability for mass fl ow rate is +/- 0.15% ; ValidCal Diagnostics to validate calibration in the fi eld; and gas accuracy is +/- 1°C (1.8°F).
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TRICOR Coriolis Technology (USA) is pleased to announce the release of their new 3” Coriolis fl ow meter to add to their TCM series. This meter is particularly well suited to the Oil & Gas Industry in applications such as measuring the midstream transportation of oil and gas, rail car and truck loading, allocation metering in crude oil and natural gas production, and metering of refi ned products in downstream production applications, as well as a whole host of other industries.
The new fl ow meter can measure fl ows 230,000 kg/hr, (8,433 lbs/min) or 230,000 lph (1012 gpm / 34,700 Bbl/day), and withstand pressures up to 1450 psi (100 bar) with a high degree of accuracy (0.1% of reading). This new meter will soon have the following hazardous area certifi cations: ATEX Ex IIC TI-T6, and CSA/cUS Class 1 Div 1.
“We are very pleased to offer this new 3” Coriolis meter to the fl ow measurement industry and our customers who’ve been asking for it. Our development engineers have meticulously designed this new size for the best possible accuracy and resistance to external vibration. TRICOR will continue to develop this TCM Series with more sizes in accordance to our customers’ needs,” stated Mark Iverson, TRICOR Program Director.
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Air Flow Meters Now with Full Suite of Global Agency Approvals
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New 3” Coriolis Flow Meter is Latest Addition to Flow Meter Series
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