New Product Alert: METTLER TOLEDO Thornton's 6000TOCi Total Organic Carbon

The 6000TOCi is a new, continuous measurement, TOC (total organic
carbon) sensor manufactured by METTLER TOLDEDO Thornton. The sensor provides
continuous, real-time measurements in pure and ultrapure waters. It uses
advanced UV oxidation technology that provides a very rapid response time.

Total Organic Carbon monitoring is vital for the measurement and control of organics contamination in pure and ultrapure waters used in industries such as pharmaceuticals, microelectronics and power generation.

To ensure changes in TOC levels are not missed, constant results are required. The 6000TOCi sensor uses conductivity measurements before and after oxidation of organic material via ultraviolet light to provide continuous, real-time determination of TOC.

Flexibility of the 6000TOCi allows installation anywhere on a water system, with the option to display results at the point of measurement or at a more convenient location for operators.

The METTLER TOLDEDO Thornton 6000TOCi Total Organic Carbon sensor has a response time of less than one minute and provides continuous monitoring, which is a huge advantage over batch measurement systems that take six minutes or longer to deliver just a snapshot of water quality.

For more information, contact Alliance Technical Sales by visiting https://alliancets.com or by calling 630-321-9646.

Understanding Refraction

This pencil appears to bend when it enters
the water because of the change in the light
ray speed as the medium changes.

Refraction is the directional change of wave propagation caused by a change in the light beams transmission medium.

Light rays travel through space in a straight line at approximately 300,000 km/s. As light passes through a transparent medium, such as water or glass, its speed is decreased.

For glass, its reduced to 200,000 kilometers per second, and for water the speed is 225,000 kilometers per second.

If the light enters into a medium perpendicular to the surface, it passes straight through but at a slower speed. However if the light beam arrives at the medium surface at an angle, not only will it speed be reduced, but it will bend due to a process called refraction.

As a beam of light reaches the surface of a medium the lower portion enters first and is slow down. However, the upper portion is still traveling at the speed of light until it arrives at the surface and enters. This speed difference at the top and bottom aspects of the light path causes it to pivot, bending toward what is referred to as the normal. This is an imaginary line drawn perpendicularly to the surface of the material.
 
Transparent materials have what is called a refractive index. This is the speed at which light travels in a medium compared to like traveling in a vacuum.
   
For example, typical glass has a refractive index of 1.33. This is calculated by dividing the speed of light in a vacuum (300,000 km/s) by the speed of light in glass (225,000 km/s).
   
The refractive index of air is 1.0003. Anytime a light beam travels from a medium with a low index of refraction, like air, to a medium with a higher index of refraction, like glass, the beam of light will bend toward the normal.
   
Likewise when the beam of light exits a highly refractive medium into a medium with the low index of refraction, the process is reversed.
   
The bottom portion of the beam of light exits first, and resumes at the speed of light, with the top portion still at the speed determined by the medium. This causes the beam to pivot away from the normal line.

Instruments used to measure the refractive index are called refractometers. Refractometers used in industrial automated systems are referred to as inline refractometers.

Jogler Industrial Level Measurement Products Catalog

Jogler is a manufacturer of process control instrumentation specializing in level control devices: site flow indicators, sight glass level indicators, magnetic level gauges, magnetostrictive transmitters, laser level transmitters and specific gravity analyzers. Jogler, LLC is a certified ASME boiler code facility and carries the U, UM and S stamps that are required via ASME boiler code section B31.1 and B31.3.

Jogler products include:

• Magnetic Level Gauges and Accessories
• Magnetostrictive Level Transmitters
• Laser Level Transmitters
• Direct-Reading Liquid Level Indicators

Download a copy of the Jogler Industrial Level Measurement Products Catalog here, or view in the embedded document below.

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Jogler Industrial Level Measurement Products Catalog from Alliance Technical Sales, Inc.

The Preparation of Pharmaceutical Waters

While the public considers municipal water to be “pure”, the pharmaceutical market considers municipal water (feedwater) just the starting point in producing pure water. Water is the most widely used excipient in pharmaceutical manufacturing, and pharmaceutical water is a multi-functional resource, crossing all disciplines in the pharmaceutical industry. Water is used as a raw material, solvent, ingredient, reagent, and clean-ing agent, and is produced in a variety of “pure” forms.

Purified Water (PW), Highly Purified Water (HPW), and Water for Injection (WFI) used in pharmaceutical processes are produced on site from the local potable water, which has been produced by the treatment of the feedwater.

This best practice guide, titled "Pharmaceutical Waters Guide for Regulatory Compliance, Analysis and Real-Time Release" and produced by Mettler Toledo Thornton, provides insight on the following topics:

DOWNLOAD THE FULL GUIDE HERE.

Pharma Waters Overview

• The Preparation of Pharmaceutical Waters
• Pharmacopeia Overview
• Industry Trends for Pharmaceutical Waters

Process Analytical Technology (PAT) and Intelligent Sensor Management (ISM)

• Ensuring Pharmaceutical Water Compliance in a PAT Environment

Total Organic Carbon

• Total Organic Carbon Measurement is a Key Control Point for Pharmaceutical Water Systems
• Improving Water System Performance Continuous Real-Time TOC Measurements
• Case Study: Real-Time TOC Analysis Safeguards Water Purity
• Case Study: In-line TOC Monitoring: Reduces Production Downtime
• Case Study: Leading Water Treatment Solution Provider Chooses METTLER TOLEDO Thornton
• The Value of Measuring TOC in CIP and Cleaning Validation Applications

Conductivity/Resistivity

• Ensuring the Absence of Ionic Impurities with Conductivity/Resistivity Measurements
• Calibration Solutions for Pharmaceutical Waters
• Case Study: Clean in Place Systems Manufacturer Relies on METTLER TOLEDO

Ozone

• Reliable, Cost-effective Sanitization the Power of Ozone
• Application and Control of Ozone Sanitization for Pharmaceutical Waters
• Case Study: Critical Ozone Measurement in Purified Water Systems

DOWNLOAD THE FULL GUIDE HERE.

Surface Heating for Analytical and Scientific Instrumentation

Electric surface heating for
analytical and scientific
applications. (BriskHeat) 

In many research & development and laboratory applications, surface heat is required to successfully conduct experiments and tests. The heat may be required for a number of reasons:

• Temperature Compensation - Varying results due to temperature fluctuation are eliminated when the temperature is constant over several repetitions or tests.
• Vacuum Bake-out - Heat helps release moisture and impurities/particulates in a closed system to allow the test results to be more accurate and consistent.
• Temperature Elevation - A higher temperature may be required to generate the desired results.

The document below, courtesy of BriskHeat, provides electric heating solutions for various laboratory applications where analytical and scientific apparatus require heat. You can also  download a PDF of "Surface Heating for Analytical and Scientific Instrumentation" here.

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630-321-9646

Surface Heating for Analytical and Scientific Instrumentation from Alliance Technical Sales, Inc.

UniCond Sensor Measures Conductivity of Water with Varying Purity Levels & Temperatures

UniCond Sensor

As the video below will show you, Mettler Toledo Thornton's UniCond sensors provide three significant advantages over other conductivity sensors:

1) Unmatched Accuracy - a self-contained measuring circuit which produces a robust output digital signal that is reliable over very long cable and certified factory calibration and temperature compensation with ASTM traceability stored in the sensor's internal memory to ensure highest installed accuracy out of the box.

2) Widest Rangeability - A single 2-electrode UniCond sensor can measure from ultrapure water all the way up to sea water with high accuracy. This significantly simplifies the specification, installation and spare parts inventory for water treatment systems. 4-electrode UniCond sensors cover the higher conductivity ranges of acid and base ion exchange regeneration chemicals.

3) Maintenance-free Performance - Mettler Toledo Thornton conductivity sensors for pure water provide high accuracy measurements with widely spaced electrodes that do not trap ion exchange resin particles, corrosion particles or bubbles, and yield more reliable, maintenance-free operation than with other sensors.

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Operating Principles of the Jogler Model ILT-6000 Magnetostrictive Level Transmitter

The Jogler ILT-6000 Direct Insertion Magnetostrictive Level Transmitter is a loop powered non-contact level measurement device that can be installed directly into a process vessel. Utilizing the magnetostrictive principle and time-of-flight calculations allow the ILT-6000 to provide a fast and accurate measurement of float position and, ultimately, liquid level in the gauge. The ILT-6000 is installed in an isolation well assembly allowing the transmitter to be removed, serviced, or replaced with no process interruption.

The video below briefly explains how it operates:

ILT-6000 FEATURES

• 2 wire, loop powered (24VDC nominal)
• LCD Display (4-20mA, %, in, and/or cm)
• Generic HART communication
• Quick-Cal function for simple recalibration
• Isolated from process pressure
• Long Measuring Lengths (up to 35ft)
• Isolation Well assembly
• Dual level outputs (total level and interface)
• Epoxy-Coated Aluminum Enclosure
• Class I, Division 1, Groups A, B, C, D
• Class II and Class III, Division 1, Groups E, F, G
• Class I, Division 2, Groups A, B, C, D
• Class II and Class III, Division 2, Groups E, F, G
• Intrinsically Safe Class I / II / III, Division 1, Groups A, B, C, D, E, F, G
• NEMA 4X

Alliance Technical Sales

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Process Refractometers Used in Industry

Technician adjusts process refractometer in plant.
(Electron Machine)

Process refractometers provide the analysis to quickly, reliably, and very accurately identify a sample and determine it's concentration and purity levels. They measure the refractive index and temperature of flowing liquids, and apply mathematical functions to determine the concentration of dissolved solids.

Part physics, part material science and part chemistry, refractometry is the process which measures the composition of known substances by means of calculating their respective refractive indexes (RI).  Light bends and changes velocity as it travels from one media into another through the media interface. When light traveling through air enters liquid, the light rays change direction by an amount determined by the liquid's density. RIs are evaluated via a refractometer, a device which measures the curve, or refraction. The
unitless number given by the refractometer, usually between 1.3000 and 1.7000, is the RI. The composition of substances is then determined when the RI is compared to a standard curve specific to the material of the substance. Standard tables are available that correlate RI to a variety of materials. These same tables also correlate RI to varying concentrations of particular liquid media at a particular temperature. Take corn syrup for example. Different refractive indexes are observed for different corn syrup samples of different concentrations. Therefore, by using a process refractometer to observe the RI of a particular corn syrup sample, a determination of the concentration of that particular sample can be made. By referring to the table or scale that correlates the RI to concentration at a particular fixed temperature, liquid concentration can be determined.

Common industrial refractometer applications are:

Process refractometer with flanged spool adapter.
(Electron Machine)

• Calculating amount of sugar dissolved in juices and beverages.
• In commercial food applications such as juice production or tomato processing, refractometers are used to measure degrees Brix (the Brix scale relates refractive index to sugar concentration, and is a key way to maintain consistency).
• In the pharmaceutical industry, process refractometers are used to monitor and control concentration levels during supersaturation, a critical process in crystallization.
• In pulp and paper production, process refractometers for measuring dissolved solids in black and green liquor during the chemical recovery process.

Equipment manufacturers have developed numerous refractometer configurations tailored to specific each use and application. Each has a set of features making it the advantageous choice for its intended application. Product specialists are invaluable sources of information and assistance to potential refractometer users seeking to match the best equipment to their application or process.

For more information on industrial refractometers, contact Alliance Technical Sales by visiting https://alliancets.com or by calling 630-321-9646.

Cloth Heating Jackets for Pipes, Tees, Valves, Fittings, and other Process Equipment

Cloth heating jacket (Briskheat)

Industrial heating applications are numerous and varied. Heating requirements can range from freeze protection to precise maintenance of process temperature in piping, equipment, or vessels. Two commonly employed heating sources are electric resistance heaters and plant steam. While each has certain advantages, steam may not always be available or practical. Electric heat offers a number of positive attributes.

• Ease of design and installation
• Precise control
• Uniform heating across surfaces
• Low maintenance requirement
• Portability
• Economical to purchase and install
• Wide array of shapes, sizes, and configurations
• Standard and custom products for every application

Cloth heating jackets are one of many electric heater variants. Formed to fit specific valves, fittings, or other items, these reusable heaters are comprised of an exterior of rugged fabric, a layer of thermal insulation, a heating blanket, and an electrical connection point or fitting. Hook and loop fasteners facilitate the unwrapping or opening of the jacket to allow for installation and removal. The surface remains cool to the touch for most applications. Control can be provided by any type of temperature controller, with prewired options available for inclusion with the heating jacket.

Construction of cloth heating jacket (click for larger view).

Liner and Facing Material (Inside and Outside cloth material)

• PTFE - Standard facing material. Exposure temperatures up to 500°F (260°C). Up to Class 10 environments. 
• BriskClean - For cleanroom class 10. Exposure temperatures up to 600°F (315°C). 
• Silicone Cloth Adds a degree of moisture and chemical resistance. Exposure temperatures up to 500°F (260°C).
• Samox® -High temperature cloth. Exposure temperatures up to 1100°F (593°C). Up to Class 100 environments.
• Aluminum- Facing material option. Exposure temperatures up to 450°F (232°C).
• Fiberglass cloth - Liner material option. Exposure temperatures up to 900°F (482°C). Up to Class 100 environments.

Closure Options

• Hook and loop fastener
• Hook and lace
• Grommets

Insulation (placed in between liner and facing)

• Fits your application based upon process temperatures. BriskHeat's industry leading engineers will design your system with the correct amount of insulation. Insulation will make your system energy efficient and touch-safe.

Voltage Options

• 120 - 600VAC
• Single phase
• 3 Phase (Wye)
• 3 Phase (Delta)
• 60 Hz.
• 50 Hz.
• DC

Power Plug / Connector Options

• Mate-N-Lock
• Twist lock
• CPC connector
• Bare wire
• Other electrical connections available

Built-in Controlling / High-limit Safety Thermostat Options

• 180°F (82°C)
• 248°F (120°C)
• 302°F (150°C)
• 347°F (175°C)
• 392°F (200°C)
• 500°F (260°C)
• Other temperatures available

Built-in Temperature Sensor Options

• Platinum RTD
• Type J thermocouple
• Type K thermocouple
• Thermistor
• Other temperature sensors available

Built-in Low-Limit Alarm Thermostat Options

• 180°F (82°C) with 30°F (17°C) differential
• 248°F (120°C) with 50°F (28°C) differential
• Other temperatures available

Accurate, Easy-to-Calibrate Online Turbidity Monitoring Solution with a Low Cost of Ownership

MTOL+ is the next generation of online turbidimeters from HF scientific. The MTOL+ Online Process Turbidimeter has been specifically designed to meet regulations of EPA 180.1 and ISO 7027.

Benefits:

• Fast and Easy Calibration - Primary calibration can be completed in less than 5 minutes.
• Low Volume Sample Chamber - Reduces calibration costs and provides quick response times.
• Long Lasting Light Source - Field replaceable if necessary.
• Low Maintenance Fail Safe Design - Simple modular design. Easy to operate & service. No external controller needed.
• Bubble Rejection System - Eliminates bubbles without delaying response time.
• Value - High quality with many features.

New Features:

• Data logging and storage of 1 year’s measurement and calibration data
• Variable user-selectable logging interval from 1 to 60 minutes
• Download data via USB
• Software updates via USB
• Isolated 4-20mA output standard
• 4-20mA and RS-485 Modbus outputs simultaneously
• Ultrasonic cleaning standard

Alliance Technical Sales
https://alliancets.com
630-321-9646

Analytical Measurement Solutions for Optimization of Your Brewing Process

Stages of brewing and areas for process measurement.

The beer market is currently experiencing an intense globalization process, reflected in escalating competitive and cost pressures. In addition to this, there is growing diversification into new, innovative beverages that demand maximum production flexibility. The time to market is becoming ever shorter, and product quality has to be guaranteed at a consistently high level, accompanied by an increase in productivity.

In-line Measurements in the Brew House

Proper process control plays a vital role in determining the flavor, foam stability, and color of the finished beer. The relative measurement sensors are exposed to high temperatures, and solid particles and turbidity constituents, and must be capable of surviving multiple CIP cycles.

Turbidity Sensor

Measurements in the Fermentation and Storage Cellars

At standard fermentation temperatures, propagation of microorganisms is detrimental to the beer. In order to prevent this from occurring, hygienic plant design and use of materials resistant to CIP solutions are important criteria, as they are for in-line sensors.

DO and CO2 Sensors

Measurements in CIP Systems

The economic use of fresh water, as well as the multiple use of cleaning solutions, present a further basis for achieving overall cost reduction in line with the strive for greater efficiency of the brewing process. Here also, in-line systems are of help in monitoring and optimizing the relative sub-processes.

Measurements in Wastewater Treatment Facilities

Fouling of sensors in wastewater leads to uncertainty about the measurement results and can even result in measurement system failure. METTLER TOLEDO provides efficient and practical solutions in the wastewater treatment areas as well.

You can download the full "Analytical Measurement Solutions for Optimization of Your Brewing Process" brochure here, or view it in the embedded document below.

Analytical Measurement Solutions for Optimization of Your Brewing Process from Alliance Technical Sales, Inc.

A Little Shameless Self-Promotion

Comments from Alliance Technical Sales customers and principals.

Established in 2000, Alliance Technical Sales, Inc. is a manufacturers’ representative agency providing numerous process control instrumentation solutions to customers across a wide range of industries.

https://alliancets.com
630-321-9646

Electric Heaters Designed for Intermediate Bulk Containers (IBCs)

Wrap-Around IBC Tote Tank Heaters
(Briskheat)

Intermediate Bulk Containers (IBCs), also known as IBC totes, or pallet tanks, are reusable industrial containers designed for the transport and storage of bulk liquid or granulated chemicals, food ingredients, solvents,  pharmaceuticals, or other material.

Often, to maintain optimum viscosity, there is need to apply heat to the contents of a tote to raise and maintain it's temperature.  This ensures the material remains ready for production and is easy to dispense. Without external heat, increased production cost or damage to equipment can occur. Heaters are also used to protect temperature sensitive material inside the IBC tote from cold or freezing, thus reducing the possibility of loss due to ruined materials.

The most effective way to heat IBCs are with specialized electric heaters referred to as "wrap-around IBC tote tank heaters". These heaters are adjustable to fit many size totes, provide the required wattage to maintain a temperature between 50 deg. F and 160 deg. F. and also include built-in 1/4” fiberglass insulation for thermal efficiency. They can be used with caged, plastic, or metal IBC tote tanks. Installation and secure fit are accommodated with adjustable nylon straps and buckles.

As the contents of the tote empties, there is no reason to continue to heat it's upper zone, so IBC heaters include independent, dual zone temperature control that separately controls the upper and lower zones of the bottle.  A built-in high limit thermostat and a grounded heating element prevents overheating and worry-free operation. A standard 120 volt, grounded 3-prong plug is provided for easy power connection (240V models have bare wires).

Silicone Rubber IBC Tote Tank Heaters
(Briskheat)

An alternative design are silicone rubber IBC tote tank heaters, for use on totes with removable bottles. Placed inside the IBC cage, directly under, and in direct contact with the bottle, they provide very fast and efficient heat-up. Made from fiberglass reinforced silicone rubber and 1/2” thick foam padding, these heaters provide outstanding durability. This design comes complete with a grounded heating element, thermocouple temperature sensor, and digital temperature controller, and is approved for use indoors and outdoors.

Common Uses for IBC Totes:

• Lubricants/Oils
• Solvents
• Detergents
• Adhesives
• Liquid/Granulated/Powdered Food Ingredients 
• Honey/Syrup/Molasses
• Chemicals

For information on any IBC, tote, or tank heating application, contact Alliance Technical Sales by visiting https://alliancets.com or calling 630-321-9646

Features of Magnetic Level Gauges (Magnetic Level Indicators)

Magnetic Level Gauge
(Jogler)

Magnetic level gauges, also known as magnetic level indicators, are routinely used to provide a display of liquid level in tanks and other vessels. Their popularity stems from their high visibility from distances and non-invasive design which reduces the possibility of leak points and the risks of fugitive emissions.



"Mag Gauge" construction is fairly simple. A magnetic float, designed for the specific gravity of the material being measured, rides inside a vertical pipe on top of the process media. A gauge with magnetically coupled visual indicator is fastened to the pipe. As the media inside the pipe rises and falls, the visual indicator moves in the same fashion.



Magnetic level gauges are often employed in tandem with magnetostrictive, guided wave radar, or other measurement means to provide a reliable local display of liquid level, as well as an electrical signal that can be transmitted to recording instrumentation or controllers.


The features of magnetic level gauges include:

• Low maintenance. 
• Wide operating temperature and pressure range.
• Visual tank level indication. 
• Continuous level measurement.
• Easier to read from greater distance than glass sight gauges. 
• Can be applied to wide fluid level ranges with a single instrument. 
• Break resistant, sturdy.
• Wide range of construction materials available.
• External mounting of ancillary indicators, switches, and transmitters with isolation from process media. 
• No electric power required for operation.

There are a number of options available so you can customize the level indicator for each specific application.  The best way to proceed is to combine your process knowledge with that of a product specialist.  Collectively, you'll be able to achieve an effective solution to your application challenge.

Industrial Corrosion Protection Through Chemical Treatment

"An ounce of prevention is worth a pound of cure", particularly when dealing with corrosion and it's effects on process equipment. Production downtime, safety concerns, environmental damage and personnel health all outweigh the obvious repair and replacement cost of the damaged equipment. All taken, the annual costs due to corrosion are estimated in the process and power industries are estimated to be around $750 billion globally.

Exterior treatments, such as painting and specialized coatings provide satisfactory results to maintain structural integrity. However, internal protection of process equipment requires a different approach. Building equipment from exotic materials which are immune from corrosion exceed any practical concept of reasonable cost. Another, much more reasonable approach is corrosion protection based on chemical treatment.

This guide, courtesy of Mettler-Toledo Process Analytics shows you the role in-line analytics play in keeping corrosion under control and avoiding unnecessary chemicals consumption in chemical plants, refineries, power and Cogen facilities.

Your local Process Analytics specialist can help you select the best equipment and strategy. Their experience and knowledge will save you time, money, and ensure quality. 

Learn How a pH Sensor Works

pH Sensor (Mettler)

The video below will provide you with a basic visual understanding of the design of pH sensors and the principles behind pH probe operation. Before viewing the video, here are some pH basics:

What is pH measurement?

pH (potential of hydrogen) is a figure used to express the acidity or alkalinity of a solution on a logarithmic scale. On this scale 7 is neutral; lower values are more acidic and higher values are more alkaline, with a maximum measurement of 14. In process applications, pH is generally measured with an inline pH probe, the most common being the glass combination electrode. Additionally, an inline pH probe generally requires a process adaption, cable and transmitter.

How does a pH probe work?

A typical combination pH probe is made up of two separate electrodes built into one, a pH sensing electrode, and a reference electrode. In the simplest terms, a pH sensing electrode uses a special pH sensing glass membrane. H+ ions permeate the membrane creating a charge. The potential between the two electrodes is the measurement of hydrogen ions in the solution, giving the measure of pH. For more details, download the free pH Theory Guide.

What is the difference between a pH probe, a pH sensor and a pH electrode?

Absolutely nothing! The three terms are used interchangeably in the industry. They can be used for probes that are used in-process or in laboratory measurement. You may also hear the term "pH meter". This can be used for a piece of laboratory equipment, or the term pH meter can also be used to mean the combination of an inline pH probe, cable and transmitter.

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Alliance Adds Thornton to Process Analytical Instrument Offering

Alliance Technical Sales, experienced provider of process analytical solutions throughout many industries, has added the Thornton brand of instruments to expand its offering of Mettler Toledo analytical products. Thornton specializes in on-line liquid process measurement solutions for pure and ultrapure water applications. The product line includes instrumentation and sensors providing high quality measurement of conductivity/resistivity, TOC, pH, ORP, dissolved oxygen, dissolved ozone, sodium, silica and bioburden. The Thornton line complements and expands the extent of Mettler Toledo products already available from Alliance Technical Sales.

Share your fluid process analytical challenges with product application experts, combining your process knowledge and experience with their product application expertise to develop effective solutions.

Process Analytics Product Catalog from Alliance Technical Sales, Inc.

Combustion Control in Gas Turbines

Proper inlet air control can boost gas turbine efficiency

Gas turbines continue to enjoy an expansion in their use throughout the world. The benefits of using gas as a fuel are well recognized. Achieving high levels of fuel efficiency will be a goal of every operator, so understanding the nature of combustion and fuels can be useful in attaining optimum operating conditions.

Vaisala, a globally recognized leader in the measurement of temperature and humidity, was authored a white paper application note that explains how the temperature and humidity of inlet air can contribute to combustion efficiency, as well as providing recommendations for measuring these parameters in gas turbine applications.

The white paper is included below. Share your process measurement requirements and challenges with application experts. Combine your process knowledge with their product application expertise to deliver effective solutions.

Optimizing gas turbine performance with precise humidity measurements from Alliance Technical Sales, Inc.

Close Temperature Control of a Process Fluid Flow

Temperature sensor is one component
of a successful temperature control
system
Courtesy Smart Sensors, Inc.

Temperature control is a common operation in the industrial arena. Its application can range across solids, liquids, and gases. The dynamics of a particular operation will influence the selection of instruments and equipment to meet the project requirements. In addition to general performance requirements, safety should always be a consideration in the design of a temperature control system involving enough energy to damage the system or create a hazardous condition.

Let's narrow the application range to non-flammable flowing fluids that require elevated temperatures. In the interest of clarity, this illustration is presented without any complicating factors that may be encountered in actual practice. Much of what is presented here, however, will apply universally to other scenarios.

What are the considerations for specifying the right equipment?

KNOW YOUR FLOW

First and foremost, you must have complete understanding of certain characteristics of the fluid.

• Specific Heat - The amount of heat input required to increase the temperature of a mass unit of the media by one degree.
• Minimum Inlet Temperature - The lowest media temperature entering the process and requiring heating to a setpoint. Use the worst (coldest) case anticipated.
• Mass Flow Rate - An element in the calculation for total heat requirement. If the flow rate will vary, use the maximum anticipated flow.
• Maximum Required Outlet Temperature - Used with minimum inlet temperature in the calculation of the maximum heat input required.

SELECT SYSTEM COMPONENTS WITH PERFORMANCE TO MATCH THE PROJECT

• Heat Source - If temperature control with little deviation from a setpoint is your goal, electric heat will likely be your heating source of choice. It responds quickly to changes in a control signal and the output can be adjusted in very small increments to achieve a close balance between process heat requirement and actual heat input. 
• Sensor - Sensor selection is critical to attaining close temperature control. There are many factors to consider, well beyond the scope of this article, but the ability of the sensor to rapidly detect small changes in media temperature is a key element of a successful project. Attention should be given to the sensor containment, or sheath, the mass of the materials surrounding the sensor that are part of the assembly, along with the accuracy of the sensor.
• Sensor Location - The location of the temperature sensor will be a key factor in control system performance. The sensing element should be placed where it will be exposed to the genuine process condition, avoiding effects of recently heated fluid that may have not completely mixed with the balance of the media. Locate too close to the heater and there may be anomalies caused by the heater. A sensor installed too distant from the heater may respond too slowly. Remember that the heating assembly, in whatever form it may take, is a source of disturbance to the process. It is important to detect the impact of the disturbance as early and accurately as possible.
• Controller - The controller should provide an output that is compatible with the heater power controller and have the capability to provide a continuously varying signal or one that can be very rapidly cycled. There are many other features that can be incorporated into the controller for alarms, display, and other useful functions. These have little bearing on the actual control of the process, but can provide useful information to the opeartor. 
• Power Controller - A great advantage of electric heaters is their compatibility with very rapid cycling or other adjustments to their input power. A power controller that varies the total power to the heater in very small increments will allow for fine tuning the heat input to the process.
• Performance Monitoring - Depending upon the critical nature of the heating activity to overall process performance, it may be useful to monitor not only the media temperature, but aspects of heater or controller performance that indicate the devices are working. Knowing something is not working sooner, rather than later, is generally beneficial. Controllers usually have some sort of sensor failure notification built in. Heater operation can be monitored my measurement of the circuit current.
  
  

SAFETY CONSIDERATIONS

Any industrial heater assembly is capable of producing surface temperatures hot enough to cause trouble. Monitoring process and heater performance and operation, providing backup safety controls, is necessary to reduce the probability of damage or catastrophe.

• High Fluid Temperature - An independent sensor can monitor process fluid temperature, with instrumentation providing an alert and limit controllers taking action if unexpected limits are reached.
• Heater Temperature - Monitoring the heater sheath temperature can provide warning of a number of failure conditions, such as low fluid flow, no fluid present, or power controller failure. A proper response activity should be automatically executed when unsafe or unanticipated conditions occur.
• Media Present - There are a number of ways to directly or indirectly determine whether media is present. The media, whether gaseous or liquid, is necessary to maintain an operational connection between the heater assembly and the sensor. 
• Flow Present - Whether gaseous or liquid media, flow is necessary to keep most industrial heaters from burning out. Understand the limitations and operating requirements of the heating assembly employed and make sure those conditions are maintained. 
• Heater Immersion - Heaters intended for immersion in liquid may have watt density ratings that will produce excessive or damaging element temperatures if operated in air. Strategic location of a temperature sensor may be sufficient to detect whether a portion of the heater assembly is operating in air. An automatic protective response should be provided in the control scheme for this condition.

Each of the items mentioned above is due careful consideration for an industrial fluid heating application. Your particular process will present its own set of specific temperature sensing challenges with respect to performance and safety. Share your requirements with temperature sensing experts, combining your process knowledge with their expertise to develop safe and effective solutions.

Direct Insertion Gaseous Oxygen Sensor - No Sampling

Ingold 6800G insertion sensor for gaseous oxygen
Courtesy Mettler Toledo

Gas phase oxygen measurement is used industrially for process safety and the prevention of oxidation. The ability to obtain oxygen level readings in real time can be advantageous in both application classes. While numerous measurement methods are available, Ingold (Mettler Toledo) provides a rugged and robust solution in their direct insertion sensors. Some measurement systems require gas sampling or conditioning, but the Ingold sensor is inserted directly into the process to provide fast and accurate oxygen readings. Coupling the direct insertion feature with Ingold's Intelligent Sensor Management delivers fast and direct O2 measurements with minimized maintenance, no sampling or conditioning, and limited downtime.

There is more to be learned. Reach out to a product application specialist and share your O2 measurement challenges. Combine your process knowledge with their product application expertise to develop the best solutions.

Gas phase oxygen measurement systems from Alliance Technical Sales, Inc.