Direct Reading Level Indicator Gauge for Process Tanks

Direct reading level gauge continuously indicates
tank liquid level
Image courtesy Jogler

Anytime there is a process tank, there is a need to know how full it may be. There are numerous methods and technologies that can be applied, with varying levels of complexity and accuracy, to provide a measure and indication of tank liquid level.

A direct reading tank level gauge is essentially an extension of the tank that provides a visible indication of liquid level. The level is not inferred from a pressure reading or tank weight, nor is it represented by the movement of a float or other device. The actual process liquid can be seen by an operator or technician by looking at the clear display area of the gauge.

A direct reading level gauge connects to tank fittings at significantly high and low points along the tank side wall. The connections permit process liquid to flow into the gauge, with the level in the gauge being the same as that in the tank. A scale on the gauge provides a reference point for liquid level that can be recorded or used in other ways in the process. The simple device has no moving parts, requires no calibration, demands little to no maintenance. It can be the primary level indicating device for a manually operated fill, or act as a backup or local indicator for an automated process.

There are pressure limitations for these indicators. Higher pressure applications, or those with liquids that may foul the clear viewing area of the indicator are better handled with a magnetic level indicator. Like all instruments, proper application is the key to getting the best performance.

Share your level measurement and indication requirements and challenges with process measurement specialists, combining your own process knowledge and experience with their product application expertise to develop effective solutions.

Level Gauges, Flow Sight Glasses, and Analyzers from Alliance Technical Sales, Inc.

Heated Impulse Lines on Pressure Gauges and Transmitters

Successive cutaway view of self-regulating heat trace

cable showing various layers of material

Courtesy BriskHeat

Temperature of the environment surrounding process equipment and instruments can sometimes have a deleterious impact on its function. A common example is cold weather impact on the impulse lines connecting pressure gauges or transmitters to process piping in outdoor or unheated locations. While the process lines may be large, with sufficient mass flow and insulation to prevent freezing, this may not be the case for small diameter impulse lines. Liquid freezing in cold weather conditions can be a threat to process operation, depending on the type of liquid being used. A safeguard exists for impulse lines where the lines can be traced with a heat source, allowing for counteraction of the environmental conditions and maintenance of proper operation.

There are a number of ways to deliver heat to an impulse line. Recognize two essential goals, with the first being to prevent freezing or other changes to the fluid in the line that would impact the response or accuracy of the instrument reading. The second goal is related to the heat tracing itself. The delivered heat must not be great enough to impact the fluid in the impulse line and generate a false pressure reading. Optimally, delivering heat in a fashion that is limited to what is necessary to maintain the impulse line fluid in an ideal working state is best.

One example of heat tracing an impulse line is through the placement of a tube or small diameter pipe, located in close proximity to line, through which low pressure steam flows. Insulation is applied to the bundle and the steam line serves as a heat source. The tube transfers heat to the impulse line when steam flows. After the steam heats the impulse line, a steam trap accompanying the system collects condensate for return to the boiler. It is also conceivable that the steam line could ultimately vent to atmosphere, with no condensate return. There are a number of concerns that must be addressed in the design of the steam portion of this scenario, since it would be necessary to keep any condensate from freezing under all anticipated operating conditions, including process shutdown.

A second common solution for freeze protection of impulse lines is through the installation of electric heat tracing. Two-wire cable serves as protection against the cold. When powered, the heat from the cable keeps the line warm. Electric heat tracing is available in a broad range of physical configurations, including cables, tape, blankets, and other flexible and solid shapes. Control of the electric heat system can be accomplished with an external controller and sensor, or a self-regulating heat trace cable can be used. As with a steam heating system, there are some specific considerations for electric heat tracing. Thermal insulation is still considered a best practice. Electric power must be delivered to the installation, and a means of monitoring heat trace performance for faults or failure should be included in the design.

Share your heat tracing requirements and challenges for process piping and other industrial applications with a product specialist. There are many options and product variants from which to choose. A consultation can help direct you to the best solution.

Water Quality Testing - Turbidity Standards

ProCal turbidity standards are suitable for use
with instruments from other manufacturers.
Image Courtesy HF Scientific

Turbidity is a commonly measured indicator of water quality. Regardless of the instrument being used, frequent and regular calibration is part of the procedure assuring accurate and traceable results that may be used as evidence of regulatory compliance.

Calibration requires the use of a prepared sample of a known value. HF Scientific, manufacturer of water quality instrumentation, reagents, and standards, provides high quality premixed turbidity standards that are suitable for use with their instruments, as well as those of several other manufacturers.

Share your water quality analysis requirements and challenges with process analytic specialists, combining your own experience and knowledge with their product application expertise to develop effective solutions.

Turbidity Standards for Turbidity Measurement from Alliance Technical Sales, Inc.

Liquid Level Measurement Using Hydrostatic Pressure

Hydrostatic pressure can be used to measure liquid level
in tanks or other vessels.

Pressure measurement is an inferential way to determine the height of a column of liquid in a vessel in process control. The vertical height of the fluid is directly proportional to the pressure at the bottom of the column, meaning the amount of pressure at the bottom of the column, due to gravity, relies on a constant to indicate a measurement. Regardless of whether the vessel is shaped like a funnel, a tube, a rectangle, or a concave polygon, the relationship between the height of the column and the accumulated fluid pressure is constant. Weight density depends on the liquid being measured, but the same method is used to determine the pressure.

A common method for measuring hydrostatic pressure is a simple gauge. The gauge is installed at the bottom of a vessel containing a column of liquid and returns a measurement in force per unit area units, such as PSI. Gauges can also be calibrated to return measurement in units representing the height of liquid since the linear relationship between the liquid height and the pressure. The particular density of a liquid allows for a calculation of specific gravity, which expresses how dense the liquid is when compared to water. Calculating the level or depth of a column of milk in a food and beverage industry storage vessel requires the hydrostatic pressure and the density of the milk. With these values, along with some constants, the depth of the liquid can be calculated.

The liquid depth measurement can be combined with known dimensions of the holding vessel to calculate the volume of liquid in the container. One measurement is made and combined with a host of constants to determine liquid volume. The density of the liquid must be constant in order for this method to be effective. Density variation would render the hydrostatic pressure measurement unreliable, so the method is best applied to operations where the liquid density is known and constant.

Interestingly, changes in liquid density will have no effect on measurement of liquid mass as opposed to volume as long as the area of the vessel being used to store the liquid remains constant. If a liquid inside a vessel that’s partially full were to experience a temperature increase, resulting in an expansion of volume with correspondingly lower density, the transmitter will be able to still calculate the exact mass of the liquid since the increase in the physical amount of liquid is proportional to a decrease in the liquid’s density. The intersecting relationships between the process variables in hydrostatic pressure measurement demonstrate both the flexibility of process instrumentation and how consistently reliable measurements depend on a number of process related factors.

Solutions to process instrumentation and measurement challenges are most effective when developed in concert with a product application specialist. The combination of user knowledge and experience with product application expertise will lead to a successful project.

Online Chlorine Monitor

Online chlorine and TRO analyzer
Photo courtesy HF Scientific

Online chlorine analyzers are utilized throughout industrial and commercial applications for the monitoring and control of chlorine in potable water, seawater, swimming pool water, process water, waste water, food processing, pulp and paper, and more. Every application benefits from instrumentation delivering accurate and reliable results with a minimum amount of human intervention.

Many instruments are available, with each possibly having a set of construction and operational features that will make it an advantageous choice for a particular application or installation.

The CLX-XT2 online chlorine monitor from HF Scientific is optimized for high temperature marine applications and provides extended reagent life and unattended operation of up to 90 days. The instrument includes communications and output signals that can be used to control chemical feed pumps or provide alarm function.

More detail on the unit is provided below. Share your analytical measurement challenges with application specialists, combining your own knowledge and experience with their instrumentation application expertise to develop effective solutions.

Online Chlorine and TRO Monitor from Classic Controls, Inc.

Water Quality Analysis – Constituent Survey Part 3

Industrial steam turbines can be negatively impacted
by silica

What we know as “water” can consist of many non-H2O components in addition to pure water. This three part series has touched on some of the constituents of water that are of interest to various industrial processors. The first installment reviewed dissolved oxygen and chloride. The second article covered sulfates, sodium, and ammonia.

To conclude the three part series on water quality analysis in process control related industrial applications we examine silica, another element which in sufficient quantities can become a confounding variable in water for industrial use. In natural settings, silica, or silicon dioxide, is a plentiful compound. Its presence in water provides a basis for some corrosion-inhibiting products, as well as conditioners and detergents. Problems arise, however, when high concentrates of silica complicate industrial processes which are not designed to accommodate elevated levels. Specifically, silica is capable of disrupting processes related to boilers and turbines. In environments involving high temperature, elevated pressure, or both, silica can form crystalline deposits on machinery surfaces. This inhibits the operation of turbines and also interferes with heat transfer. These deposits can result in many complications, ranging through process disruption, decreased efficiency, and resources being expended for repairs.

The silica content in water used in potentially affected processes needs to be sufficiently low in order to maintain rated function and performance. Silica analyzers provide continuous measurement and monitoring of silica levels. The analyzers detect and allow mitigation of silica in the initial stages of raw material acquisition or introduction to prevent undue disruption of the process. Additionally, a technique called power steam quality monitoring allows for the aforementioned turbine-specific inhibition – related to silica conglomerates reducing efficacy and physical movement – to be curtailed without much issue. The feedwater filtration couples with a low maintenance requirement, resulting in reduced downtime of analytic sequences and a bit of increased peace of mind for the technical operator.

While silica and the other compounds mentioned in this series are naturally occurring, the support systems in place to expertly control the quality of water is the most basic requirement for harvesting one of the earth’s most precious resources for use. As a matter of fact, the identification and control of compounds in water – both entering the industrial process and exiting the industrial process – demonstrates key tenets of process control fundamentals: precision, accuracy, durability, and technological excellence paired with ingenuity to create the best outcome not just one time, but each time.

The measurement of the various contaminating constituents of process water requires special equipment and techniques. Share your water quality measurement requirements and challenges with fluid process specialists, combining your own knowledge and experience with their product application expertise to develop effective solutions.

Water Quality Analysis – Constituent Survey (Part 2)

Sewage treatment is but one area where water quality
measurement is employed

It would be difficult to understate the role and importance of water in industrial processing, even our own biological existence. In the first installment of this series, the roles of dissolved oxygen and chlorides were covered.

Continuing the examination of water quality monitoring in municipal and industrial processes, another key variable which requires monitoring for industrial water use is sulfate. Sulfate is a combination of sulfur and oxygen, salts of sulfuric acid. Similarly to chlorides, they can impact water utilization processes due to their capability for corrosion. The power generation industry is particularly attuned to the role of sulfates in their steam cycle, as should be any boiler operator. Minerals can concentrate in steam drums and accelerate corrosion. Thanks to advancements in monitoring technology, instruments are available which monitor for both chlorides (covered in the previous installment in this series) and sulfates with minimal supervision needed by the operator, ensuring accurate detection of constituent levels outside of an acceptable range. Ionic separation technologies precisely appraise the amount of sulfate ions in the stream, allowing for continuous evaluation and for corrective action to be taken early-on, avoiding expensive repairs and downtime.

Another substance worthy of measurement and monitoring in process water is sodium. Pure water production equipment, specifically cation exchange units, can be performance monitored with an online sodium analyzer. Output from the cation bed containing sodium, an indication of deteriorating performance, can be diverted and the bed regenerated. Steam production and power generation operations also benefit from sodium monitoring in an effort to combat corrosion in turbines, steam tubes, and other components. Sodium analyzers are very sensitive, able to detect trace levels.

Ammonia is comprised of nitrogen and hydrogen and, while colorless, carries a distinct odor. Industries such as agriculture utilize ammonia for fertilizing purposes, and many other specializations, including food processing, chemical synthesis, and metal finishing, utilize ammonia for their procedural and product-oriented needs. An essential understanding of ammonia, however, includes the fact that the chemical is deadly to many forms of aquatic life. Removing ammonia from industrial wastewater is a processing burden of many industries due to the environmental toxicity.

Methods for removing ammonia from wastewater include a biological treatment method called ‘conventional activated sludge’, aeration, sequencing batch reactor, and ion exchange. Several methods exist for in-line or sample based measurement of ammonia concentration in water. Each has particular procedures, dependencies, and limitations which must be considered for each application in order to put the most useful measurement method into operation.

As water is an essential part of almost every facet of human endeavor and the environment in which we all dwell, the study and application of related analytics is an important component of many water based processes. The variety of compounds which can be considered contaminants or harmful elements when dissolved or contained in water presents multiple challenges for engineers and process operators.

Alliance Technical Sales specializes in the instruments, equipment, and supplies utilized to analyze water and other liquids employed throughout commercial and industrial operations.