FEATURE FLOW, LEVEL & CONTROL
LEVEL AND FLOW INSTRUMENTATION Applications in petrochemical and ethylene plants
Magnetrol produces a wide range of level and flow instruments that have provided measurement solutions to some of the complex issues facing petrochemical and ethylene plants
M
anaging petrochemical and ethylene plants requires monitoring a variety
of complex processes. Preventing accidents is a key concern, as well as ensuring that no product is lost and that the highest quality is maintained. The level and flow devices used to monitor these processes often makes a significant impact on plant efficiency and safety. Magnetrol produces a wide range of level
and flow instrumentation that can be used in petrochemical and ethylene plants. The company has shared stories from different plants that improved their petrochemical production and better monitored their facilities by using Magnetrol products.
NOT ALL GUIDED WAVE RADAR IS CREATED EQUAL One of the world’s largest oil & gas and petrochemical companies was having problems with multiphase applications involving hydrocarbon level with water bottoms and gas vapour space. Guided wave radar (GWR) technology was introduced to monitor these applications. However, the GWR devices selected did not produce a reliable signal throughout the measurement range, and the dynamics of the interface made it difficult to distinguish between the upper level and the water below. There was a threat of loss of primary containment (LOPC) due to these measurement errors. Magnetrol pioneered GWR technology for level measurement and its latest
device, the Eclipse Model 706, is considered the highest performing GWR level transmitter on the market. The Eclipse Model 706 was tested side-by- side with multiple GWR competitors for both top level and interface measurements and it was proven to be best-in-class. The Eclipse 706 tracked level up to the device’s flanged process connection, above 100 per cent level, with no dead zones or blind spots at the top of the probe. It prevented LOPC by tracking the top hydrocarbon level through the vapour space and also measured the interface (water bottom) due to the superior signal strength. In summary, it was the only device tested that could produce reliable measurements with a completely dry probe, a probe having only one of the two process media present, and under varying interface conditions.
MEASURING BLANKETING GAS TO REDUCE COST An oil & gas and petrochemical company in China required nitrogen tank blanketing for their flammable liquid containment. Monitoring the nitrogen was essential to account for leakage and verify flow going into the vapour space of the tanks. Due to the number of tanks, the gas flow was monitored to find the right balance between the necessary nitrogen usage and potential cost savings. Magnetrol recommended its Thermatel TA2 thermal mass flow meters to monitor
the nitrogen for tank blanketing. The meters came fully calibrated and configured so the company could simply install them and power up. Thermatel TA2 flow meters are very effective in extreme low gas pressures, such as in tank blanketing applications. In addition, total cost of ownership was reduced with calibration verification procedures that could be performed in the field. Since calibrations can cost tens of thousands of pounds and cause process downtime or loss of measurement, this saved money and increased efficiency for the company.
MAINTAINING BALANCE IN ETHYLENE PLANTS In ethylene plants, balancing environment, health and safety is essential while maximising productivity. Each part of the ethylene production process has its own challenges and considerations when it comes to monitoring level and ensuring safety and efficiency. Proper level instrumentation can improve this process and bring peace of mind to plant operators.
VISUAL LEVEL INDICATION IN CRYOGENIC APPLICATIONS An ethylene plant in China required a clear visual indication of level from challenging cryogenic applications including methane, ethane, ethylene and propylene. Specific gravity in these applications ranged from 0.3-0.8. The plant needed a level indicator that could withstand these challenging conditions and provide unobstructed visual indication. The Orion Instruments Atlas Magnetic
Level Indicator (MLI) has physical floats in the MLI chamber that can simultaneously meet cryogenic and low specific gravity requirements. The careful float design allows level to be tracked accurately even as temperature and specific gravity shifts. Cryogenic visual flags or indicators, also
known as frost shields, prevent frosting to provide a clear visual indication of liquid level. By using Atlas in their applications, the plant was able to obtain the clear visual level indication that was required.
A Thermatel TA2 monitoring gas flow in a petrochemical plant
16 DECEMBER/JANUARY 2018 | INSTRUMENTATION
MEETING SAFETY REQUIREMENTS A refinery and petrochemical facility in Canada that primarily produces ethylene needed to upgrade its level
/ INSTRUMENTATION
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