By Lydia Miller, Rosemount Level Senior Marketing Engineer, Emerson Automation Solutions
Hi! I’m Lydia Miller with Emerson Automation Solutions, and I’d like to share a few reasons for you to attend this year’s Emerson Exchange in October. This year the Emerson Global Users Exchange will be in Minneapolis, MN, from October 2nd through the 6th. There are usually around 3000 reasons to go (that is the approximate number of attendees, and each one has something great to share). Since it is in my backyard, I would love for everyone to come to my house for a picnic – but since I can’t manage the numbers, here are some of my favorite reasons for you to attend this amazing event.
#1 The Technology Exhibit!! This is a wonderful opportunity to see products you may be specifying, ask experts detailed questions about products and applications, see what is new and learn about everything that Emerson can offer you for process automation.
#2 The Music Jam. Okay, this one is all fun and no products, unless Emerson sells guitars, ukuleles and tambourines (they don’t). But it is great to see people come together with minimal practice time as a group and have so much fun and actually sound pretty darn good. My tambourine skills aside, everyone is pretty impressive. If you have any music background, be sure to sign up and participate. Or just show up and experience the collaboration.
#3 The workshops and short courses. Although this is third on the list, it is not third in my heart (I can’t give them all #1 status). There are over 300 different courses. These are presented by end users and industry experts willing to share their stories about solving the most challenging process controls problems, following best practices for plant performance optimization, or increasing the safety and reliability of operations (just to name a few topics).
#4 Tour of the Rosemount Global Headquarters. When else can you get a sneak peek at everything that goes into making Rosemount products reliable? It will be worth the stay until Friday.
#5 Meet the Experts. You can meet with a panel of experts and ask them about all of your most pressing overfill protection issues. Or other topics such as alarm management, controls upgrades, and process control optimization – oh, my!
This year, the theme is Powering Collaboration. Registration is now open with an extended early bird pricing until August 31st (previously August 15th). Just register and collaborate with the best that process automation has to offer.
Why attend? You can check out the link to get more info on why to attend, if my list of favorites leaves you wanting more. Hope to see you there!
By Amanda Gogates, Cascade Global Product Manager, Emerson Automation Solutions
Precise and cost-effective measurement of gas purity significantly impacts the bottom line in a number of industrial applications. I’d like to share a new technology with you that will overcome many of the most common problems manufacturers face in this area, including poor sensitivity, costly consumables, and outmoded equipment requiring high levels of technician resourcing to operate and maintain. You may be aware of the Emerson line of Quantum Cascade Laser (QCL) technology for measurement applications such as Continuous Emission Monitoring or CEMS. Now, this remarkable technology has been extended to some of the most demanding markets in the world and is a quantum leap over previous generation solutions.
First, a little background on the technology. Emerson’s QCL technology offers fast, high-resolution spectroscopic detection to identify a range of compounds. QCLs operate in the mid-infrared spectral region, where molecules typically exhibit strong absorption bands that can be exploited to improve measurement sensitivity. Coupled with Tunable Diode Laser (TDL) spectroscopy, a single instrument is now able to broaden measurement capability and exploit both the near- and mid-infrared regions. The result is that a single analyzer is able to monitor an increased number of compounds compared to preceding technologies. The system uses what is called a laser chirp technique. In this technique, a QCL is pulsed with electrical energy and heats up and as the temperature increases, the wavelength of the emitted light also increases. A laser chirp lasts about one microsecond, and in this time a spectrum of between one and three wavenumbers is scanned, sufficient to detect unique absorption features from one or multiple gases. This data can then be interpreted in terms of absolute concentration, minimizing the need for complex and frequent instrument calibration. QCLs can be chirped at a frequency of up to 100 KHz, enabling many thousands of spectra to be gathered in a few seconds, resulting in a high signal-to-noise ratio, while maintaining a rapid response time.
As a result of this unique design, the new CT5800 enables highly accurate measurement of concentrations of impurities down to sub-ppm levels in a variety of gas streams. This makes it ideal for hydrogen purity, nitrogen purity, and ethylene purity applications. With up to six laser modules housed inside the same enclosure, the CT5800 analyzer can measure up to twelve components simultaneously, greatly reducing the need for multiple analyzers while still meeting the real-world analysis needs of these markets.
The key outcome of this new technology is that the combination of this measurement performance and analyzer capabilities has not been possible before – not with existing lasers or other measurement technologies. Of course, not every application needs this level of performance, but when taking the example of ethylene product quality, time and product contamination is money in this volatile industry. When multiple, highly sensitive measurements can be made in seconds by a QCL, excursions in the product quality can be rapidly detected, facilitating decisions to suitably manage plant operation, and minimize losses. QCL technology provides a speed and quality level never before possible. Likewise, the low levels of detection not only improve product quality for the user, but they also open up wider market options and help meet guidelines.
Over the next months, I’ll be sharing about ways to optimize gas analysis in different critical markets. For now, if you have questions about how QCL technology might work for you, please contact me at Amanda.gogates@Emerson.com.
By Johan Sandberg, Safety Expert, Emerson Automation Solutions
As you know, overfills are a major problem to the process industry in general, but especially so for bulk liquid storage tanks where the consequences can be catastrophic. The industry and society in general are currently investing considerable resources to increase the safety at tank farms. Today the basic overfill prevention technology at many facilities with atmospheric bulk liquid storage tanks uses this configuration:
This is the recommended minimum configuration for most tank operations according to API 2350.
Two trends – continuous level for the OPS-sensor and Radar technology for the ATG – are now converging and new installations today often consist of two radar level gauges for both level and independent overfill prevention measurements. Two of the main reasons behind this transition is the high reliability of radar technology combined with the efficient proof-testing procedure it offers. Because of the online measurement the latest generation of Radar level gauges can offer remote proof-testing capabilities. However, existing tanks often have practical limitations that make safety upgrades with two separate level gauges cost prohibited:
That’s where a new technology pioneered by Emerson comes in with a solution. Rosemount 5900 2-in-1 Radar Level Gauge is a new technology that allows a single tank opening to be used for both level (ATG) and separate overfill prevention (OPS-Sensor) measurements. This solution offers substantial cost savings compared to using two separate level sensors.
We’d like to offer you a free white paper that walks you through the issues related to overfill protection, the regulatory requirements and the ways in which this novel solution might work for your tank installations. Please click HERE for the white paper.
If you have any questions, just contact Johan Sandberg, Johan.Sandberg@Emerson.com or call +46703740705. What are the issues you face in improving safety in bulk liquid storage?
By Bonnie Crossland, Product Manager, Gas Chromatographs, Emerson Automation Solutions
As you may know, by January 30, 2019, 40 CFR Part 63 requires that petroleum refinery owners or operators of flares used as control devices for emissions points must meet the requirements of §63.670, regardless of the construction date of the flare. The regulation is part of the 1990 Clean Air Act that regulated emission standards for hazardous air pollutants (HAP) and is in addition to 40 CFR 60 Subpart Ja requirements. 40 CFR Part 63 regulations require determining the concentration of individual components in the flare vent gas within 15 minutes or direct monitoring of the net heating value of the flare vent gas at standard conditions.
I’m happy to tell you that Emerson Automation Solutions has developed two standard solutions that are compliant with 40 CFR Part 63 using its Rosemount 1500XA gas chromatograph (GC).
Why use a GC? Generally, you can consider three possible approaches when trying to meet petroleum refinery flare requirements – a calorimeter, a mass spectrometer, or a GC. A calorimeter is a relatively low-cost instrument, the measurement principle of which is burning the gas and measuring the heat generated. It has analysis time in the seconds range and simple maintenance, which all sounds very desirable. However, it requires a shelter for outdoor use, which adds significantly to its cost, and most important, it provides no information on what’s happening in the process or what’s going up the stack. Without composition information, there’s no way to determine which unit is generating the flare gases, which limits your response to a flare event.
A mass spectrometer provides individual component concentrations within the flare but at a very hefty price. Likewise, it requires a shelter, and is very difficult to maintain, often requiring a calibration gas for every component as well as a multicomponent blend. It usually requires monthly adjustments with notoriously high operating costs.
Which brings us to the GC solution. Like the mass spectrometer, the GC provides individual components (including isomers) within the flare but without the high price. The Emerson GC specifically requires no enclosure (saving even more money), it’s easy to maintain with simple thermal conductivity detectors (TCDs) for this application, provides information on what’s happening in the process through its easy-to-use software, and it provides updates well within 40 CFR Part 63 requirements.
Emerson Rosemount’s 1500XA gas chromatograph offers the greatest flexibility in measuring, calculating, and recording the individual component concentrations present in the flare vent gas. Emerson is offering two standard 8-minute solutions using the Rosemount 1500XA with multiple TCDs to meet the requirements of 40 CFR Part 63, Subpart CC (Refinery MACT 1) and 40 CFR Part 63, Subpart UUU (Refinery MACT 2). Solution 1 looks at hydrocarbons, H2S, H2, CO and CO2, and Solution 2 adds benzene detection. Custom solutions that measure, calculate, and record operators’ specific flare compositions are also available.
A GC provides an efficient and cost-effective approach to meeting the 40 CFR Part 63 requirements which every petroleum refinery plant is facing. If you’d like to discuss the possible implementation in your plant, give me a call at 713.396.8832, or contact email@example.com.
By Chris Duncan, Business Manager, Emerson Automation Solutions
Detecting flammable gas that has the potential to threaten people and property in areas where gas clouds easily disperse is a problem in many applications. This recent case history is a classic example.
A UKCS (United Kingdom Continental Shelf) operator was issued an improvement notice from the Health and Safety Executive after a large volume gas leak went undetected on one of their North Sea platforms. The release had not been picked up by the platform’s existing flammable gas detection system because the gas had been dispersing as soon as it escaped.
The company contacted Emerson for help. The solution was to provide the Incus, an ultrasonic gas leak detector that, while working in conjunction with the existing gas detection system, added another line of defense and provided an early warning when gas releases occurred. Most importantly, it increased the safety of platform personnel.
Ultrasonic gas leak detection uses acoustic sensors to identify fluctuations in noise that are imperceptible to human hearing within a process environment. The sensor and electronics are able to detect these ultrasound frequencies (25 to 100KHz), while excluding audible frequencies (0 to 25KHz).
Unlike traditional gas detectors that measure the accumulated gas, ultrasonic gas detectors “hear” the leak, triggering an early warning system. The sensors respond to sound generated by escaping gas at ultrasonic frequencies. Leak rate is mainly dependent on the size of the leak and the gas pressure. In most facilities, the majority of process noise is in the audible range, while limited ultrasonic noise is generated in normal operation. Highly pressurized gas releases produce ultrasound (25-100 kHz) which the sensors are able to pick up despite the presence of audible noise. Ultrasonic (acoustic) gas leak detection technology has several advantages over conventional gas sensor technologies: it does not have to wait until a gas concentration has accumulated to potentially dangerous concentrations; it does not require a gas cloud to eventually make physical contact with a sensor; and the response is instantaneous for all gas types.
The Incus is ideally suited for monitoring outdoor applications such as on an oil platform. The Incus has been engineered to withstand even the most extreme conditions. Performance is not affected by inclement weather, wind direction, leak direction or any potential gas dilution, with an instantaneous response to all gas types. It is an excellent addition to many safety systems adding another layer of detection to existing technologies.
The Health and Safety Executive subsequently inspected the platform and approved the solution provided, resulting in a very happy customer!
Do you have an application that might require the addition of ultrasonic detection? It might be worth a discussion. Contact us HERE today.