Y

LEVEL - 3 DESIGN & ENGINEERING MANUAL

DEPARTMENT MANUAL NO.

: :

INSTRUMENTATION AND CONTROLS DESIGN EM-I-025

SUBJECT

SPECIAL INSTRUMENTS

REV. NO. 0

DATE 23.11.98

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CONTENTS

I.

INTRODUCTION

II.

GUIDELINES FOR SELECTION BASED ON SERVICE

III.

GUIDELINES FOR SELECTION OF MATERIAL OF CONSTRUCTION.

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I.

INTRODUCTION

Based on the physical and chemical properties of matter, the analysers could be broadly classified in to 4 catagories that the matter is having some interaction with energy. These energy states which may be characteristics of any chemical composition and this external energy source may be in any of the following basic groups. 1. 2. 3. 4. Electromagnetic Radiation Chemical affinity or Reactivity Electric or Magnetic fields Thermal or Mechanical energy Group - I Group - II Group - III Group - IV

GROUP I

Measurement of the quantity and quality of electromagnetic radiation emitted, reflected, transmitted or diffracted by the sample, by which the molecular composition of solid, liquid, or gas may be analysed. Determination of chemical composition by measurement of the reaction product with other chemicals in terms of amount of sample or reactant consumed, product formed or thermal energy liberated or determination of equilibrium attained is the basis for most of the classical methods of qualitative and quantitative chemical analysis. Several instrumental methods have been applied to this technique and it involves two steps. a) Promotion of a chemical reaction. b) Measurement of a reaction product as a means for determining the presence and quantity of a particular constituent in the sample.

GROUP II

GROUP III

Measurement of the current, voltage, or flux change produced in the energised electric and magnetic circuits containing the sample. The production of net electric charges on atoms or molecules by bombardment with ionizing particles or radiation or by electrolysis or dissociation in solution or the induction of dipoles by strong fields establishes measurable relationships between these ion.

GROUP IV

Measurements of the results of applying thermal or mechanical energy to a system in terms of energy transmission, work done, or changes in physical state. Thermodynamic relationship involving the physical state and thermal energy content of any substance permits analysis and identification of mixture of solids, liquids and gases based upon the freezing and boiling points and upon the quantitative measurement of physically separated fractions. Useful information can often be derived from thermal conductivity and viscosity measurements. Some of the Analysers which use the above principles have been explained in brief for the purpose of design and specification.

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The type of analysers covered are as follows:1. 2. pH Analyser. Oxygen Analyser. a) Zirconium probe. b) Thermal conductivity. Infra red Analysers. (for So2, Co2 etc). Thermal conductivity Analysers (for So2, Co2 etc). Electrode-less conductivity Analysers (for acid concentration). Gas chromatograph. Liquid chromatograph. Gas detectors. Hydro Carbon leakage detectors. pH Analysers.

3. 4. 5. 6. 7. 8. 9. 1.

The term pH is a convention used to indicate the acidity or alkalinity of a solution. It is obtained by determining the logarithm (base 10) of the reciprocal of hydrogen ion concentration expressed is grams/liter. A pH index, from a practical standpoint can be considered to range from 0 pH to 14 pH. The smaller the pH number greater the free acidity or hydrogen ion concentration. A solution having a pH number of 7 at 25oC is neutral. Solutions with pH below 7 are acidic and those with pH above 7 are alkaline. As the pH value increases in a given solution the hydroxyl ions increase the hydrogen ion correspondingly decrease. The decrease in pH from 14 to 1 the hydrogen ion concentration increases ten times for each unit drop in pH value. This means the 7 pH denotes ten times the activity of 8 pH. pH analyser comprises of 3 electrodes. 1. Glass electrode. 2. Reference electrode. 3. Sensing element for temp. Compensator. 1. The primary function of the Glass electrode is to develop a potential proportional to the hydrogen ion concentration. This potential is used to represent the pH value in the pH meter. The reference electrode is designed to produce a constant potential regardless of the solution in which it is immersed. For further details. Ref. API-RP-550-part-II. manual for reference.

2.

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2.

OXYGEN ANALYSER.

Oxygen Analyser can be divided into two types. 1. 2. Paramagnetic property of oxygen. Chemical methods.

1. Analyzers working on paramagnetic principle admits gases in vicinity of a hot wire inside a non uniform magnetic field, then the gas is heated reducing its magnetic susceptibility causing it to be displaced by the incoming cooler gas experiencing a strong magnetic force thus a form of wind is created, thus there was a flow of oxygen molecules drawing other molecules with them and causing cooling of one coil and heating of the other. The change in resistance of the coils was monitored and calibrated in percentage of oxygen. 2. a) Chemical method.

This method is suitable for the determination of oxygen content in non combustible gases or saturated hydrocarbons. The method is based upon the measurement of the change in temperature due to the total catalytic combustion of the oxygen in the sample with hydrogen. b) Thermal Conductivity. Hydrogen has a very high thermal conductivity and it also reacts catalytically with oxygen. These properties of hydrogen are the basis of the inferential thermal conductivity, method. The sample gas at room temperatures mixed with a constant stream of hydrogen. The mixer is admitted to one chamber of a dual thermal conductivity detector, after which the oxygen in the sample is reacted with the hydrogen in a suitable oven to form water. The remaining mixer after the removal of its water content is admitted to the second chamber of the detector. The unbalance in the conductivity bridge is directly proportional to the oxygen concentration. 3. INFRA RED ANALYZERS

There are two major groups of infra red Analysers depending upon the means of wavelength selection. 1) 2) The dispersive type. The non dispersive type.

The development of the narrow-band pass interference filter (Single or Selectable wave length) created a third catagory called (3) optional interference filter Analyzer. I. DISPERSIVE TYPE INFRA RED ANALYSER

The instrument uses a grating Monochromator with two entrance slits to yield two wavelengths, one monochromator at the measuring wavelength of the desired component in the liquid sample and one monochromator at an appropriate reference wavelength. The flow through the sample has a secondary cell as a protective device in case of leaks. The detector is a radiation thermocouple as used in laboratory instruments. process analyser is rugged and long term quantitative analysis. The

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2.

NON DISPERSIVE TYPE

This arrangement uses two matched sources operating approximately 800 oC. An opaque (usually) chopper modulator blocks both sources simultaneously with equal ONOFF period with a frequency as low as 2 HZ. The sample cell is highly polished tube that conducts the radiant energy through it by multiple reflection. The gaseous sample from the process flows continuously through this cell. The reference cell is similar but generally is used only to transmit the radiant signal and is simply filled with inert gas. The radiant energy then passes into the pneumatic microphone detector. The detector is a sealed chamber with the very thin flexible diaphragm separating the two halves exposed to each beam. Thus changing the relative pressure in the two chambers. The pressure change deflects the flexible diaphragm which forms a variable capacitor plate in an electric circuit. 3. Band pass optical filter Analyzer.

This instrument can be built to operate in the entire infra-red region. The variable wavelength wedge type interference filter analyzer simplifies the monochromator portion of a dispersive-type analyzer. The filter replaces the entire monochromator in its function of isolating the operating wavelength. 4. THERMAL CONDUCTIVITY ANALYZERS

A wheatstone bridge is the form of network employed to measure the resistance change of the sensing element. The current used to energise the bridge also serve for heating the wire. It is common practice to use two cells in adjacent arms, one of the cells containing the reference gas and other containing the gas to be analyzed. The bridge then responds to the difference in temperature rise (ie resistance) of the two sensing elements and thus is dependent upon the difference in thermal conductivities of the gases in the two cells. 5. ELECTRODELESS CONDUCTIVITY ANALYSER

Electrodeless type conductivity cells are ideally suited where the use of conventional electrode type cells is difficult, impractical, or even impossible due to the nature of the solution being measured. Solutions which are oily, corrosive, abrasive, or which contain entangling fibres are natural applications for the electrodeless cell. Maintenance problems associated with such solutions are reduced to a minimum allowing years of uninterrupted service. Designed for continuous in line measurement of salt, caustic, and acid solutions. Applications include concentration monitoring of sea water, plant effluents or any solution that cass foul conventional conductivity electrodes. The cell construction includes 1 or 11 NPT male process fitting. Material include PVC, polypropelene or CPVC process fittings of these materials or of metal such as SS316 stainless steel integral temperature compensation is also provided.

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6.

GAS CHROMATOGRAPH.

The gas chromatograph is a device which is used for making qualitative and quantitative analysers of selected stream components and for promptly supplying information equivalent to that obtained from a refinery control laboratory. The purpose of the gas chromatograph is to determine the quantities of individual components or combinations of components to the extent necessary for intelligent operation of a process. It can be used for the following. 1. 2. 3. 4. Single Key Component Analysis. Multi Component Analysis (Single Stream) Complete Analysis (Single Stream) Multistream Analysis (either partial or complete).

A gas chromatograph employs elements for separating the sample into components and for identifying and measuring those components. In simplest terms, the gas chromatograph is a tube (Column) packed or coated with a material that exerts different retarding effects on the components of a gas or vapour sample passing through it. Hence the components of a mixture introduced as a batch at one end of the column and transported through the column by a moving carrier gas will be separated. The components will emerge from the downstream end of the column at different times, but all the molecules of a given component will emerge together within a narrow time span. A sensitive detector is employed at the column outlet in order to reveal the presence and concentration of emerging components. The detector signal may be displayed on a strip chart recorder in the form of deflection peaks. 7. LIQUID CHROMATOGRAPH

The operating conditions are very stringent and the sample valves for liquids should be precise and the volume of sample allowed must be between 0.2 to 20 Micro liters, and must not vary more than 1 percent for successive samples. Certain construction features are incorporated, the connection to the column is as short as possible because the volume of the trap section is so small, its diameter may restrict and venting through the valve and increase Lag. Depending upon the volume of the System, an auxiliary parallel vent may be necessary with upstream connection located as close to sample valve entry as possible. Partition columns are used in gas - liquid chromatography for separating complex hydrocarbon samples. The separating medium (the column packing) is a granular solid impregnated with a liquid substrate that is essentially non-volatile under the conditions of use. The packing appears to be dry but in reality exposes a large liquid surface to the vaporised sample component as they are bourne through the column by the carrier gas. The sample components are partitioned between the gas and liquid phases. Those components least soluble in the liquid pass rapidly through the columns and emerge early. Those components most soluble in the liquid are retarded and emerged later. The most volatile components generally emerge earliest. The versatility of gas-liquid chromatography is a result of the large variety of liquids that can be used to obtain different separations.

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II. 1)

GUIDELINES FOR SELECTION BASED ON SERVICE a) Analyser design Considerations.

Many factors are involved in providing a complete analyzer system. The installation must
q q

meet all safety requirements. to obtain an accurate and reliable analysis. to provide facilities for necessary testing, calibration and isolation and for economical maintenance. Designed for lowest cost commensurate with required performance.

b) A Thermal Conductivity Analyser has to be used for continuous automatic gas Analysis. The sample which is Thermally Conductive shoulde be highly pure. It is necessary to avoid significant changes in composition of the sample as it passes through the sampling, cleaning and conditioning system. This may impose necessary limitations on the type of cleaning operation feasible and it may be necessary to accept additional maintenance in order to deliver a chemically significant sample for analysis. The most frequent cause for delivery of contaminated or diluted sample is air infiltation obtained by suction at some point in the sampling system. The essential information for selecting the right analyser are The stream to be sampled and the data to be obtained for the following objectives in mind.
q q q q q

operator information only. operators information and corrective action. Direct process control. Study information. Management information. LIQUID - GAS CHROMATOGRAPHS

2)

These Analysers are selected for a) Single key component Analysers. b) Multi-component Analysis. c) Complete Analysis (single stream). d) Multi-stream Analysis. 3) INFRA-RED ANALYSERS

Infra-red analysers are selected for liquid or vapour phase analysis in concentrations from low parts per million to several percent. IR is one of the most widely used analytical techniques. Most of the infra red process analysers utilize selective infra red absorption by the component of interest in the
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representative sample. Among the few materials that do not absorb wavelengths are oxygen, nitrogen, hydrogen and the halogens. pH ANAYLSERS

at

some infra red

pH analysers are used for the measurement and control of hydrogen ion concentration for some of the common applications like.
q q q q q q

Refinery Waste water. Cooling tower water. Boiler feed water. Codensate in fractionator reflux systems. Corrosion Control in processing facilities. Chemical Neutralization etc.

OXYGEN ANALYSERS The oxygen Analyser has become one of the leading combustion efficiency guide, since oxygen has a direct relationship with excess air.By sampling flue gases, the operator can use minimum amount of air for complete combustion and yet obtain the fullest utilization of the fuel burned. Another combustion application is the monitoring of the oxygen content of the fuel gases from fluid catalytic cracking regenerators. Percentage of oxygen in inert purge or Blanketing gas. When an inert gas is manufactured or used to purge or blanket vessels, it may be desirable to have a continuous analysis of the oxygen content of the purging gas prior to admission of the gas to the system. It is also a good practice to monitor the oxygen content of the inert gas blanket inside of a processing equipment when there is a possibility when inadvertent admission of air inside the storage tanks could cause degradation of the contents of the tank or permit an explosive mixture to exist. GAS CHROMATOGRAPH The purpose of the gas chromatograph is to determine quantities of individual components or combinations of component to the extent necessary for the intelligent operation of a process. The analyser is broadly applied to mixtures of organic and inorganic materials and is particularly useful with mixtures of compounds whose chemical characteristics (composition and molecular structure) and whose physical properties (boiling point, density) are so nearly identical as to make other separation and analytical techniques difficult or impractical. Chromatography is used widely in the Laboratory for organic chemicals, biological and medical studies and in Industry chemical, petroleum and petrochemical plants for quality and process control. Chromatograph is a complex transducer which not only puts out a signal that identifies the types and amounts of given substances by separating the target substances

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from a stream that may contain numerous other substances, some of which may be closely related physically and chemically. GAS DETECTOR Gas detector is a system capable of detecting a variety of conbustible and Toxic gases and also to continuously analyze a sample atmosphere to detect the presence of flammable gases or vapours up to their Lower explosive limit (LEL) in air adapted to meet industrial requirements, the system helps to protect life health and property by automatically detecting, indicating recording and warning of flammable gas hazards. Combustible Gas detection system can be located at single or multiple locations at a distance up to 5000 ft. The heart of the combustible Gas detection system is a unique remote sensing head assembly specifically designed for area monitoring. The assembly consists of condulet containing a sensing head and a terminal strip to complete the connection to a control unit. Detectors mounted in the sensing head comprise two elements of a bridge circuit that are exposed to the atmosphere of the area under surveillance. Each detector consists of a small ceramic bead supported on a coil of platinum wire and these are designated as P element sensor units. One p element unit is active because it is coated with a special catalyst material that causes the combustible gas or vapour to combine with oxygen at a much lower temperature than would be required for normal combustion. The other element unit is inactive this inactive p element is located in an electrically opposite bridge position from the active unit. When a mixture of flammable gas in air is brought into contact with these catalytic p element units a rapid combustion of the combustible gas takes place on the p element unit surfaces. This burning of the combustible gas increases the temperature of the p element unit creating a proportional change in its resistance. The change in resistance creates an imbalance in the bridge circuit the result of which is calibrated on a meter indicating the concentration of the combustible gases in the sample. Thus a reading on the meter of 0 to 100 % percent shows how closely the atmosphere being monitored approaches the minimum concentration required for flammable mixture. Reference. MSA catalogue on combustible gas detection System. HYDROCARBON LEAKAGE DETECTORS

Hydrocarbon Analyser is a continuous low level (0-4 PPM) multirange Monitoring instrument designed to detect and measure trace contaminants of hydrocarbon in various atmospheres. The hydrocarbon analyser can detect hydrocarbons as atmospheric pollutants,or measure automobile exhausts for hydrocarbon emissions, it can monitor atmospheres of toxic gases or vapors, gas mains or monitor fuel handling or storage areas for leakage. The operation of the analyser is based on the ionisation of carbon atoms in a hydrogen flame. Normally a flame of pure hydrogen contains an almost negligible number of ions adding organic compounds even traces results in a large number of ions in the flame. In the analyser, the sample is mixed with a hydrogen fuel and passed through a small jet Air supplied to the annular space around the jet supports combustion. Any hydrocarbon carried in to the flame results in the formation of carbon ions an electrical potential across the flame jet and an ion Collector electrode suspended above the flame produce an ion current proportional to the hydrocarbon count. This is measured by an
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electrometer circuit whose output then provides an analog analysis signal for the direct reading meter.

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D) GUIDELINES FOR SELECTION OF MATERIAL OF CONSTRUCTION pH ANALYZER has 3 electrodes namely 1. 2. 3. Glass electrode. Reference electrode. Temperature Compensator.

Applications and process requirements usually dictate the type of equipment for each pH installation. Most of the pH measuring systems utilize sensing elements which are located in one of four ways. 1. 2. 3. In a piped sample stream at atmospheric pressure. In a piped main process stream or piped sample stream at positive pressure. In a tank, trough, or stream at variable level & constant levels.

3. Sampling system for heavily contaminated oily samples containing light oil and heavy sludge. Electrode flow chambers are used to admit pH sensitive electrode assemblies directly in to piped process streams or into by pass sample streams. They may be used in streams under pressures of 150 pounds/sq.inch gage. In some instances, individual glands may be used instead of flow chambers. This permits mounting, electrodes directly in to a large process line. A more convenient method is to provide a flow chamber in a bypass. The bypass can easily be shut off and the electrode system serviced. Immersion assemblies are used in a tank, trough or open stream at constant level. The tips of the electrodes are immersed in the process fluid. The electrodes for P measurement with various services, temperature and pressure ratings. Refer M/s. Beckman Industrial catalog on Flow Configurations. of series three electrode Station Assemblies. CONDUCTIVITY ANALYSERS. Conductivity Sensor: The conductivity sensor can be threaded on to the process line or side of the tank or can be attached to the length of the pipe for submersible installation. An integral 12 feet cable is supplied for interconnection between the analyzer and transmitter and 1 - 1 inch PVC tube Tee is available for flow through construction. Process connection shall be 1 inch NPT both front and rear threads. Wetted materials. Electrode : Insulator : Gold plated Hastelloy. C Kynar or Viton.

and the pressure rating 175 psig and temperature shall be 38oC.
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Junction box : Integral cable : lugs.

ABS, meets NEMA - 4 specifications. Four conductor cable with cable shielded pair 12 foot length with spade

GAS CHROMATOGRAPH 1. 2. 3. 4. Chromatographic column shall be small bore tubing with suitable length packed with materials required for separation. The tubing material, packing solids components and the carrier gas. and liquid must be inert to all sample

Packing materials shall be having a high surface area and packed uniformly. There are two types of columns. a) Adsorption column. b) Partition columns.

Adsorption columns are selected for Gas-Solid chromatography for the Separation of fixed gases, such as nitrogen, carbon dioxide, hydrogen Sulphide. This columns can also be used to separate volatile hydrocarbons. Partition columns are used in gas-liquid chromatography. 5.0 Selection of the carrier gas is purity. 6.0 vendors responsibility but the user must ensure

There are two types of detectors namely, a) Thermal conductivity detectors. b) Flame ionization detectors.

Thermal conductivity detectors are ideal but cannot withstand shocks and vibrations. For further details refer M/s. BECKMAN CATALOG on Sample conditioners. for process Gas chromatograph system. THERMAL CONDUCTIVITY ANALYSERS 1. 2. The enclosure shall be explosion proof for using in Class-I, Groups B,C,D, Division-1, hazardous locations. The measuring device in our Thermal Conductivity gas Analysers shall be two pair of heating filaments placed in cavities within a metal block thermal conductivity cell act as a two legs of the bridge. The cells shall be made out of 316 stainless steel cells with teflon coated filaments for use with corrosive samples. The cell response time shall be 95 percent of change in 30 seconds at a sample flow rate of 3 to 21 Cu inches/min. The sampling systems shall be made out of stainless steel. The filament materials shall be either of the following material and the same can be coated with Teflon for corrosive services.
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a) b) c)

Tungston. Nickel. Platinum.

INFRA RED PROCESS ANALYSER. 1. The material of construction in general shall be designed for industrial environments with the emphasis on rugged construction with reliable and accurate performance. 2. The detector shall be rugged and solid state pyroelectric type operating at ambient temperature. 3. The process temperature shall be Max/min of 0 - 180oC and pressure shall be Max/min 0 to 150 Psig. 4. Designed for IP65 without electrical cell heater and IP50 with electrical cell heater. the cell material shall be a) 316SS. b) Monel. c) Hastelloy 276. d) other should be specified. and the cell o rings shall be. 1) Viton. 2) Chemraz. 3) PTFE.

OXYGEN ANALYSERS. There are two basic types of oxygen analysers currently more suitable for Industrial applications. 1. 2. Electro chemical. Thermal conductivity.

1. In Electrochemical type, is an electrochemical cell, consisting of a section of doped Zirconia, usually a disc or a tube whose opposite surfaces are coated with porous platinum electrodes. 2. Thermal Conductivity type. The flow of gas which results from paramagnetism has been utilised in the thermal paramagnetic oxygen analyser the cooling effect of the gas flow is used to cool the filament of a thermal conductivity cell thus changing its resistance. Materials such as stainless steels and higher alloys can be used for corrosive services. Heat resistant glass fitted with rubber connectors can also be used. For corrosive flue gas services the sample lines shall be made of 1 inch I.D. steam hose of polypropylene, polyvinyl chloride, and poly tetrafluro ethelene. Material and design Specifications for filters, separators, dryers, regulators and other sample handling components should be carefully reviewed with the Manufacturers Standards.

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GAS DETECTORS. 1. The p element detector should be selected to have a life more than 10,000 hours of operation. The life can be extended still further by operating the detector at one half the temperature of the conventional platinum wire type. 2. Separate relay may be furnished for the warning, alarm and ready functions.

3. The diffusion head shall be designed to meet the requirement of explosion proof Class-1 Group A,B,C,D division-1, as Specified by National electric code. 4. All printed circuit boards shall be conformably coated to provide resistance to salt spray and fungus. 5. The Gas detector circuit shall be provided with Electrical noise rejection, high voltage spike, and radio frequency interference protection. HYDROCARBON LEAKAGE DETECTOR 1. The sensor shall be catalytic bead combustion sensor which is available either in stainless steel or aluminium which can have reliable performance. 2. 3. 4. 5. The sensor must be fitted with dust and splash guard to suit the prevailing conditions. The metal oxide varistors should be provided to protect high voltage transients. The outputs must be having an open Collector integrated circuit installed in a socket. Reference books. 1) 2) 3) 4) Process instruments and controls handbook by Considine. API-RP 550 Analyser catalogue. Rosemount catalogue. Beckman Industrial process Analyser catalogues.

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