Six Challenges Faced by Chemical Industries for measurement and control of level

Best-In-Class Level Measurement and Control Instruments by Pune Techtrol Owing To meticulously Engineered Instruments!

Continuous upgrading of environment & safety standards, stringent quality requirements of products and cost effective operationsare some of the varied and complex challenges that chemical industries have to deal with.To meet the ever-increasing demands of customers the chemical industries have to advancetechnologically to maintain lead in the market withreliable products. For implementation of advanced technology, one needs to have expert know-how of the instrumentation and automation market, to choose the proper instruments required for the level measurement of liquid and solid materials.

Pune Techtrol is the perfect companion offering acomprehensive range of products inlevel measurements and control instrumentsas well as expert know-howfor process automation. Chemical industries need accurate and reliable level measurement and control instruments to overcome following challenges normally encountered in their operations.

1. Corrosive liquids and environment

Handling of corrosive and aggressive liquids is inevitable in chemical industries. The chemicals needed to be handled may have strong acidic and strong alkaline properties. Very often corrosive fumes may be present in the storage tanks/vessels. Level measuring instruments installed on such storage tanks must be able to function accurately for long periods. Mechanisms of high and low-level monitoring, instruments must be able to sustain corrosive environments.Manual methods of monitoring level have a risk factor resulting into human injury.To assure the smooth functioning of processes, it is essential to design instruments with precision. The cutting-edge technology provided in Pune Techtrol instruments is highly precise.Measurement Technologies:

Various “Material of Construction (MOC)” of thelevelmeasuring instruments such as SS304/316/ PP/ PVDF, PTFE coated with SS are provided to suit the corrosive nature of chemicals.

Direct reading level gauges use stainless steel, PVDF, Teflon as MOC, particularly for corrosive and toxic chemicals.

2. Safety Norms and Regulations

Safety is a critical parameter inchemical industries. Some plants in chemical industries have inherent dangers because of the reactive chemicals stored in the tanks/vessels. Measurement and control operations in respect of such processes must have minimal human involvement and hence have to be automatic or remotely controlled. Some chemicals are flammable and can cause fire hazard.  To comply with safety requirements,Techtrolinstruments are designed to meet all the safety standards. Pune Techtrolhas wide range of approved,verified, certified and tested products thatmeet all the safety standards and environmental norms and regulations.

3. Materials having Different values of viscosity, specific gravity, dielectric constant

Values of viscosity,specific gravity, dielectric constant of materials whose levels are to be monitored are very important in design and selection of appropriate instruments for particular operation.Techtrol manufactures level measuring instruments based on various principles. While designing and manufacturing the instruments the precise values of these parameters must be available from the users. Accurate values of viscosity, specific gravity, dielectric constants in turn ensure accuracy and reliability of the level monitoring instruments.Measurement Technologies:

Float type switch are based on Archimedes principle where density is important.

In case of capacitance & radar type instruments, dielectric constant must be known.

4. High temperature & pressure conditions

In chemical industry there are endothermic and exothermic processes where high temperature & pressure conditions can occur. Working in such critical conditions, plant operators require accurate &reliable solutions for monitoring applications.In such varying temperature and pressure and the aggressive media, Techtrollevel measurements and control instrumentsare capable of working satisfactorily under such conditions

Measurement Technologies:

Appropriate selection of material with sufficient mechanical strength is ensured for the instruments subjected to conditions of high temperature and pressure.

Direct reading level gauges are tested for 1.5 times the operating pressure and certified by Inspectorate of Boilers wherever necessary.

5. Presence of fumes, dust and fire hazards

The tanks storing fly-ash haveextremely hot and dusty environment. Also, some chemicals/ materials can generate fumes which may lead to fire hazards in thechemical plant. When a fine dust suspended in air is ignited a dust explosion occurs which causes a very rapid burning and can injure people.The results of the instruments must be helpful to avoid the undesired conditions. The level instruments provided by Pune Techtrol come with a robustflameproof  housing and are designed to provide accurate results in extreme conditions.

Measurement Technologies:

For fuming liquids, seal pots are provided in FBG, FDG & FTG.

For hazardous applications instruments are provided with flame-proof & ATEX certified enclosures

Non-contact type instruments based on radarprinciple have antenna made up of PVDF material..

Selection between contact and non-contact type radar is done by taking into consideration the presence of dust/fumes and dielectric constants of the chemical materials.

Zener barriers are provided for isolation wherever required.

6. Improvement in Plant Efficiency

By virtue of their accuracy and reliability Techtrol level measuring instruments play vital role in improving operational efficiency of the plant. Techtrol uses modern technology to meet the challenge of continuous improvement in level measurement in turn helping the industry to improve product quality & efficiency. Following instruments are examples of such advanced technology.

Ultrasonic transmitters an guided wave radar

Radar type level transmitter using FMCW technology

Magnetostrictive transmitters

Displacer type transmitters

A final word

Pune Techtrol, a leading manufacturer in the field has set the benchmark by its precise and reliable instruments.The team of professional and skilled engineers of Pune Techtrol, who have expertise in theselection of the appropriate level measurement and control instruments, take into account various factors required and specified by the customers.

About Pune Techtrol

Pune Techtrol,a leader in designing and manufacturing the innovative Process Automation, Level measurement and Control instruments for liquids and solids. Used by many industries and professionals for more than three decades, Pune Techtrols’ quality equipment is trustedaround the globe.

Contact Us

Pune Techtrol Pvt.Ltd

S-18, MIDC Bhosari,

Pune - 411026,India

Phone No- 020 66342900

Email Id- ho@punetechtrol.com

Website- http://www.punetechtrol.com

Using Level Transmitters for Waste Water Management- Pune Techtrol

Campaigns for water preservation and saving water are running all across the world. People are being urged to take precautionary measures while using water.Is there really a need to make such hassle around a common thing called water? The answer is an obvious yes, the reason for which stands same as our previous blogs on waste water management

Pune Techtrol Pvt. Ltd. believes in making a difference while running a company. Thus, this leading manufacturer and supplier of level measurement and control instruments customizes its products such that they serve useful in applications like waste water management.

The in-house motivation for the same can be seen when Mr. Ramesh Pabalkar, the General Manager at Pune Techtrol Pvt. Ltd. says, “The ‘water crisis’ will hit us much before the‘energy crisis’. Every opportunity for saving water and recycling treated waste water must be explored.”

The level transmitters by Pune Techtrol are instruments which prove very useful in the process of waste water management. The Techtrol Ultrasonic Transmitter (TUS) is a non-contact type level transmitter, generally used for measurement of flow in open channel or level monitoring in tanks. It is compact, non-contact, and easy to install, integral type transmitter for continuous level measurement of non-corrosive liquids and slurries. It is programmable through Keys.

Owing to its aforementioned characteristics, it proves highly useful in waste water management plants. It is used for various processes in storage tanks, filter beds, flotation cells, water / waste water/effluent treatment (WTP, ETP), etc.

About Us

Pune Techtrol Pvt. Ltd. has evolved from a six employee enterprise, in 1984 to become a premier Indian company recognized for quality level measurement and process automation systems for liquids & solids. Techtrol’ is recognized as most reliable & trusted brand, delivering quality products unsurpassed in terms of accuracy, workmanship, performance, safety & ease of installation, providing long uninterrupted service in wide & varied industrial applications

Contact Us

Pune Techtrol Pvt.Ltd

S-18, MIDC Bhosari,

Pune - 411026,India

Phone No- 020 66342900

Email Id- ho@punetechtrol.com

Website- http://www.punetechtrol.com

Steam: Major Source for heating and electricity generation

The utility of steam is multifold and can be put to use in a variety of industries for multiple purposes. Steam is a secondary source of energy since it is produced from water by combustion of any type of primary source of fuel in a boiler. Steam is produced out of a single process of energy conversion; it is a cheap source of energy.

Following characteristics of steam make it an ideal medium for heat transfer applications:

·         Efficient and economical to generate

·         Uniform heating - easy to distribute

·         Easy to control

·         Easily transferred to the process by its own pressure

·         Steam plant easy to maintain

·         Heat transfer takes place at constant temperature

The applications for steam are heating processes in plants and steam driven turbines in electric power plants, 

used by the massive petrochemical complexes to the local microbrewery, steam is an integral part of these processes.

Steam is one of the most versatile utility in the industrial energy arena today. In addition to simple heating applications, it can also be deployed in various industrial processes like cleaning, sterilization, drying, concentration, separation and evaporation.

·         In culinary applications, it preserves flavours, textures, and retains nutrients. For processing of vegetables and food, steam is used for sterilization and drying under vacuum.

·         The use of steam in the industry for the purpose of cleaning does not harm surfaces, motors, bearing seals, sensors and machinery equipment. Hence the requirement of mask off or cover equipment prior to cleaning is not there. There is very less chance of any cross-contamination and thus it helps in faster clean up.

·         The freshwater, naturally available from various sources, requires varying degrees of treatment before being fed to the boiler. Treatment of boiler feed water prevents the formation of scales and deposits, removes dissolved gases, protects against corrosion, eliminates water & steam carry-over, optimizes boiler efficiency and minimizes maintenance costs. Improper or nonexistent feed water treatment is the major cause of boiler failure.

·         In biotechnology applications, steam is produced in various grades of purity. Steam ranges in purity from boiler grade for routine tasks, to culinary grade “Clean Steam” for food and dairy, and goes up to super pure, pyrogen-free steam for biopharmaceutical and intravenous use.

·         In case of “dry saturated steam” there is a definite relationship between temperature and pressure of the steam. This characteristic of steam helps in controlling the processes precisely.

·         In the frigid oil & gas fields, steam is used for heat tracing of tanks and pipelines to keep processes moving.

Steam is a safe, flexible, economical, aseptic, and environment-friendly. Steam can be generated through combustion of fossil fuels, biomass or biogas. In the thermal power stations, steam is required to be produced in huge quantity for generation of electricity. The steam has to be produced at very high pressure (>150 kg/cm2) and high temperature (> 5400C), to produce steam in abundance, large volumes of feed water are supplied to the boiler. Although feed water cycle of a thermal power plant is a closed loop process, there is always some loss of water while it moves through the closed cycle. This loss of water has to be made up by addition of treated water into the feed water tank via de-aerator. Feed water contains dissolved oxygen, which can cause corrosion in the boiler tubes. Hence the dissolved oxygen must be removed from the feed water. This process is carried out in the de-aerator with the help of steam. De-oxygenated and heated feed water enters the boiler by means of feed water pump, where it is further treated with chemicals.

About Us

Pune Techtrol Pvt. Ltd. has evolved from a six employee enterprise, in 1984 to become a premier Indian company recognized for quality level measurement and process automation systems for liquids & solids. Techtrol’ is recognized as most reliable & trusted brand, delivering quality products unsurpassed in terms of accuracy, workmanship, performance, safety & ease of installation, providing long uninterrupted service in wide & varied industrial applications

Contact Us

Pune Techtrol Pvt.Ltd

S-18, MIDC Bhosari,

Pune - 411026,India

Phone No- 020 66342900

Email Id- ho@punetechtrol.com

Website- http://www.punetechtrol.com

Six Challenges Faced by Chemical Industries for measurement and control of level

Best-In-Class Level Measurement and Control Instruments by Pune Techtrol Owing To meticulously Engineered Instruments!

Continuous upgrading of environment & safety standards, stringent quality requirements of products and cost effective operationsare some of the varied and complex challenges that chemical industries have to deal with.To meet the ever-increasing demands of customers the chemical industries have to advancetechnologically to maintain lead in the market withreliable products. For implementation of advanced technology, one needs to have expert know-how of the instrumentation and automation market, to choose the proper instruments required for the level measurement of liquid and solid materials.

Pune Techtrol is the perfect companion offering acomprehensive range of products inlevel measurements and control instrumentsas well as expert know-howfor process automation. Chemical industries need accurate and reliable level measurement and control instruments to overcome following challenges normally encountered in their operations.

1. Corrosive liquids and environment

Handling of corrosive and aggressive liquids is inevitable in chemical industries. The chemicals needed to be handled may have strong acidic and strong alkaline properties. Very often corrosive fumes may be present in the storage tanks/vessels. Level measuring instruments installed on such storage tanks must be able to function accurately for long periods. Mechanisms of high and low-level monitoring, instruments must be able to sustain corrosive environments.Manual methods of monitoring level have a risk factor resulting into human injury.To assure the smooth functioning of processes, it is essential to design instruments with precision. The cutting-edge technology provided in Pune Techtrol instruments is highly precise.Measurement Technologies:

• Various “Material of Construction (MOC)” of thelevelmeasuring instruments such as SS304/316/ PP/ PVDF, PTFE coated with SS are provided to suit the corrosive nature of chemicals.
• Direct reading level gauges use stainless steel, PVDF, Teflon as MOC, particularly for corrosive and toxic chemicals.

2. Safety Norms and Regulations

Safety is a critical parameter inchemical industries. Some plants in chemical industries have inherent dangers because of the reactive chemicals stored in the tanks/vessels. Measurement and control operations in respect of such processes must have minimal human involvement and hence have to be automatic or remotely controlled. Some chemicals are flammable and can cause fire hazard.  To comply with safety requirements,Techtrolinstruments are designed to meet all the safety standards. Pune Techtrolhas wide range of approved,verified, certified and tested products thatmeet all the safety standards and environmental norms and regulations.

3. Materials having Different values of viscosity, specific gravity, dielectric constant

Values of viscosity,specific gravity, dielectric constant of materials whose levels are to be monitored are very important in design and selection of appropriate instruments for particular operation.Techtrol manufactures level measuring instruments based on various principles. While designing and manufacturing the instruments the precise values of these parameters must be available from the users. Accurate values of viscosity, specific gravity, dielectric constants in turn ensure accuracy and reliability of the level monitoring instruments.Measurement Technologies:

• Float type switch are based on Archimedes principle where density is important.
• In case of capacitance & radar type instruments, dielectric constant must be known.

4. High temperature & pressure conditions

In chemical industry there are endothermic and exothermic processes where high temperature & pressure conditions can occur. Working in such critical conditions, plant operators require accurate &reliable solutions for monitoring applications.In such varying temperature and pressure and the aggressive media, Techtrollevel measurements and control instrumentsare capable of working satisfactorily under such conditions

Measurement Technologies:

• Appropriate selection of material with sufficient mechanical strength is ensured for the instruments subjected to conditions of high temperature and pressure.
• Direct reading level gauges are tested for 1.5 times the operating pressure and certified by Inspectorate of Boilers wherever necessary.

5. Presence of fumes, dust and fire hazards

The tanks storing fly-ash haveextremely hot and dusty environment. Also, some chemicals/ materials can generate fumes which may lead to fire hazards in thechemical plant. When a fine dust suspended in air is ignited a dust explosion occurs which causes a very rapid burning and can injure people.The results of the instruments must be helpful to avoid the undesired conditions. The level instruments provided by Pune Techtrol come with a robustflameproof  housing and are designed to provide accurate results in extreme conditions.

Measurement Technologies:

• For fuming liquids, seal pots are provided in FBG, FDG & FTG.
• For hazardous applications instruments are provided with flame-proof & ATEX certified enclosures
• Non-contact type instruments based on radarprinciple have antenna made up of PVDF material..
• Selection between contact and non-contact type radar is done by taking into consideration the presence of dust/fumes and dielectric constants of the chemical materials.
• Zener barriers are provided for isolation wherever required.

6. Improvement in Plant Efficiency

By virtue of their accuracy and reliability Techtrol level measuring instruments play vital role in improving operational efficiency of the plant. Techtrol uses modern technology to meet the challenge of continuous improvement in level measurement in turn helping the industry to improve product quality & efficiency. Following instruments are examples of such advanced technology.

• Ultrasonic transmitters an guided wave radar
• Radar type level transmitter using FMCW technology
• Magnetostrictive transmitters
• Displacer type transmitters

A final word

Pune Techtrol, a leading manufacturer in the field has set the benchmark by its precise and reliable instruments.The team of professional and skilled engineers of Pune Techtrol, who have expertise in theselection of the appropriate level measurement and control instruments, take into account various factors required and specified by the customers.

About The Author

Mr. C.N. Shukla, Training & Development Consultant, Pune Techtrol.

About Pune Techtrol

Pune Techtrol,a leader in designing and manufacturing the innovative Process Automation, Level measurement and Control instruments for liquids and solids. Used by many industries and professionals for more than three decades, Pune Techtrols’ quality equipment is trustedaround the globe.

For Information

Contact us at ho@punetechtrol.com

Visit us at www.punetechtrol.com