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Smarter Instrument Mounting Using Close-Coupling Techniques

Posted by Process Control Team on 30 Nov 2017

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Smarter Instrument Mounting Using Close-Coupling Techniques, Application Image, Instrumentation Products DivisionInnovations in the design of primary isolation valves and manifolds for mounting pressure instrumentation can deliver enormous pressure control advantages to both instrument and piping engineers, ranging from significantly enhanced measurement accuracy, to simpler installation and reduced maintenance. Parker Hannifin has created a comprehensive range of instrument manifold mounting solutions for the main types of pressure instrumentation, employing close-coupling techniques which eliminate impulse lines and tube fittings to improve overall instrument performance and reliability.

What is close-coupling?

There is no formal definition for close-coupling, but it has come to mean any instrument mounting system that enables a user to connect an instrument directly on to the process line, and primary flow control isolation valve. The overriding objective of this is to optimise the accuracy of measurement, by eliminating the long runs of tubing, tube fittings and bends and joints between process pipe and instrument that can cause pressure drops, and gauge/ impulse line errors.

Transmitter ‘hook-ups’ are often configured individually for each application, and can be large, heavy and difficult to install. By replacing such arrangements with purpose-designed close-coupled manifold/mounting solutions, users are able to optimise accuracy and reap a whole range of additional benefits such as...

  • Increased transmitter accuracy and repeatability by eliminating impulse lines
  • Reduced size and weight, less stress on the process pipework
  • Easy winterisation, no heat traced impulse lines to power up or freeze
  • Faster installation, and the option of transmitter assembly and testing
  • Reduced maintenance, and higher instrument up time
  • Elimination of threaded connections
  • Simpler design with less components and less leak paths
  • No risk of impulse lines blocking, as impulse lines are eliminated
  • Pre engineered compact design eliminates the need for impulse line field design
Faster process measurement

‘Hook-ups’ for pressure transmitters often involve the custom configuration of complex arrangements of tubing, with multiple connections and valves. Measurement errors can be introduced as a result of long length impulse lines. These errors are frequently compounded by the use of different tube, fitting and valve components whose diameters may vary throughout an instrument installation.

Inaccuracies can distort the pressure impulse signal, causing errors of up to 15% (on flow measurements).

Smarter Instrument Mounting Using Close-Coupling Techniques, Traditional Hook Up, Instrumentation Products DivisionTraditional ‘hook-up’ for a differential pressure transmitter

This traditional solution uses two sets of valve assemblies to create the double block and bleed valves, which are connected with impulse lines and connectors to the instrument manifold. It involves numerous discrete components, with all the associated costs and assembly time, and introduces bends that cause attenuation and turbulence that can affect measurement accuracy. If not carefully specified, other measurement accuracy problems can arise from differences in bore diameters of the various components, and unequal lengths of tubing.

 

The close-coupled alternative Smarter Instrument Mounting Using Close-Coupling Techniques, Close-Couples Technique, Instrumentation Products Division
  • Short and straight flow path to instrument from the process, increases transmitter accuracy.
  • Integration of the manifold in to double block and bleed valve, eliminates numerous leak paths.
  • No hook-up drawings or Bill of Materials are required to create an instrument hook-up.
  • Assembly takes only minutes compared to hours with a conventional impulse line system.
  • Low maintenance system, which is very easy to maintain if required.
  • Smaller and lighter assembly placing much less stress on the pipework.

View the Parker Close-Coupled Instrument Mounting System here.

Smarter Instrument Mounting Using Close-Coupling Techniques, Jim Breeze, Instrumentation Products DivisionJim Breeze is Product Manager, Instrumentation Connections and Process Valves, Parker Hannifin, Instrumentation Products Division, Europe.

 

 

 

 

 

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Choosing the Right Connector, Tubing and Accessories for Your Application - Part 1

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  • THM Analysis Applications in Water Treatment. Tap water. Parker Hannifiin. Instrumentation Products Division.The quick, accurate, and inexpensive measurement of Trihalomethanes (THMs) creates numerous opportunities to improve the water treatment process. THM levels can be lowered throughout the distribution system and chemical usage can be optimized to save money. What’s more, quick process adjustments can be made to control THM formation when surface water Total Organic Carbon (TOC) characteristics alter due to seasonal or unusual weather conditions. Where before you might have had limited THM data, you can now greatly expand the sampling frequency and monitoring locations to help you better understand the THM formation characteristics of your water source, treatment process, and distribution system. 

    Surface water supply matrix changes

    Both human activities and seasonal changes can affect source water, altering the mineral characteristics of the water as well as the reactivity of its dissolved organic carbon. A water plant may observe no significant changes in the quantity of TOC due to seasonal events, but they may find their THM level has changed. Frequent measurements of THM can help operators better understand the reactivity changes of their source water. 

    Coagulant evaluation test

    A successful coagulation process depends on identifying the correct coagulant type and optimum dosage under suitable environmental conditions of pH and alkalinity such that the coagulant will remove the maximum TOC, UV254, and turbidity, and form easily settleable floc. However, without the ability to measure THM concentration of the finished water in real time, the plant operator will not know if the coagulation process has been optimized to also remove the maximum amount of THM precursors. With the ability to easily measure THM concentration in finished water, the plant operator can adjust the coagulation process to achieve minimal THM formation potential. Additionally, this allows the treatment plant to supply safe drinking water with the required level of disinfectant concentration while also maintaining lower DBP levels throughout the entire distribution system.

    Real-time monitoring of THM sampling locations

    Trihalomethane formation in water distribution systems is a function of water travel time, temperature, and physiochemical and biological characteristics of pipe deposits within the distribution system. The real-time monitoring of THM at different sampling locations will help water distribution operators to identify problematic inorganic/organic pipe deposits that cause increased levels of THM formation.

    Water quality model evaluation/water quality trend

    Hydraulic modeling of a water distribution system is an important tool for water quality management. In addition to basic hydraulic characteristics, modeling identifies water aging and predicts disinfectant decay and DBP formation. Incorporating new data from frequent THM analysis in combination with disinfectant level data will help plant operators build an improved hydraulic model for water quality trend analysis, providing critical information for more targeted and efficient water plant operation.

    Flushing program

    Water quality levels throughout the distribution system are maintained by systematic flushing programs designed to reduce stationary water in dead end lines and increase flow volume to minimize water age. The distance of water from the water plant, dead ends in the pipe, and low water usage may cause water quality deterioration. Lower residual disinfectant levels indicate the need to flush, which can cause a significant water loss. By measuring THM concentration in addition to disinfectant levels, operators can better decide on the location and length of flushing to minimize treated water loss.

    Water age evaluation

    Water age is emerging as an important issue due to increased THM formation in water distribution systems. Excessive contact time caused by dampened peak-hour demands, distribution piping configurations, areas of reduced water requirements, and fire protection storage can result in elevated THM concentration. Identifying and then reducing dead spaces and stagnation in water storage tanks and looping pipe configurations in water distribution systems will reduce water age. These actions can be triggered appropriately by monitoring THM levels in storage tanks and key locations in the distribution system.

    The Parker THM analyzers

    THM Analysis Applications in Water Treatment. On-Line THM Analyzer. Parker Hannifin. Instrumentation Products Division. Parker’s On-Line THM Analyzer and benchtop THM Analyzer are easy to operate, integrated Purge-and-Trap Gas Chromatographs (GC) that measure THM concentration at ppb levels in less than 30 minutes right at your own facility without tedious sample preparation.
    This integrated system is a powerful tool that can help operators optimize water treatment at the plant and evaluate water age in the distribution system for improved control over the formation of THMs.

    Pic. 1. Parker's On-Line THM Analyzer.

    Download Parker On-Line THM analyzer bulletin.

     

     

     

    THM Analysis Applications in Water Treatment. Bench top THM Analyzer. Parker Hannifin, Instrumentation Products Division.Pic. 2. Parker's benchtop THM Analyzer.

    Download Parker benchtop THM analyzer product catalog.

     

     

     

    THM Analysis Applications in Water Treatment. Kazi Hassan, technology development manager (water). Parker Hannifin, Instrumentation Products DivArticle contributed by Kazi Hassan - technology development manager (water) at Parker Hannifin, Instrumentation Products Division.

     

     

     

     

     

    Related content on water quality:

    How Parker's THM Analyzer Helps to Improve Safety of Drinking Water

    THM Analysis Applications in Water Treatment
    The quick, accurate, and inexpensive measurement of Trihalomethanes (THMs) creates numerous opportunities to improve the...
  • How Parker Instrumentation meets NACE requirements for materials used in the manufacture of fittings, Refinery, Instrumentation Products DivisionSince the NACE (National Association of Corrosion Engineers) MR0175 standard was updated to ISO status in December 2003, there has been an air of confusion on what and how products conform to NACE. Some manufacturers simply buried their heads and try to ignore the standard, some simply decided that they would not pursue NACE product related business, some only certify to old, out of date versions of the standard, and others simply used the wording of certain clauses within the standard as a way of supplying product from materials that do not actually meet the requirements of NACE MR0175.

    Parker has taken NACE compliance very seriously and invested a lot of time to ensure that not only did we understand the consequences of the standard but what we actually put out to our customers in the market place was accurate and met the criteria of what the standard is advising the Oil and Gas Industry.

    Engineers from Instrumentation Products Division Europe attended a conference organized by the authors of the NACE MR0175/ ISO 15156 document and arranged for one of the authors to visit our manufacturing facility at Barnstaple to discuss its implications and how we as a manufacturer of saleable goods should be certifying the materials we use for NACE compliant products.

    Declaration of Conformity 

    Meeting NACE Requirements For Materials Used In The Manufacturing Of Fittings_Declaration of Conformity_Instrumentation Products Division

     

     

     

     

     

     

     

     

     

     

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    Meeting Nace Requirements For Materials Used In The Manufacture Of FittingsArticle contributed by Clara Moyano, Innovation Engineer - Material Science at Instrumentation Products Division, Europe

    Meeting NACE Requirements For Materials Used In The Manufacture Of Fittings
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  • Reducing Fugitive Emissions - Meeting ISO Standards with Process to Instrument Valves. Petrochemical Plant. Parker Hannifin. Instrumentation Products Division Managing emissions is a major challenge for many companies. In Europe alone, a typical refinery can lose between 600 and 10,000 tonnes of fugitive emissions every year; and the majority of those losses are estimated to be caused by plant equipment, such as process to instrument valves and small bore fluid system technologies.

    Valve leakage is believed to account for around 50 per cent of emissions within the chemical and petrochemical industries. That can place a major financial burden on companies - not just due to potential plant inefficiency, but also the potential costs of repairing leaks, wasting energy and environmental fines.

    Reducing emissions can help businesses to protect the environment, reduce waste and save valuable time and money in the process. Engineering, Procurement and Construction (EPC) and end users involved in commissioning may find it helpful to follow a series of checks - alongside any existing processes - to determine prospective supplier capability.

    Adherence to international Standard ISO 15848.

    International standard ISO 15848 sets a requirement for zero emissions for processes involving hazardous fluids and volatile air pollutants. The standard is split into two parts:

    Reducing Fugitive Emissions - Meeting ISO Standards with Process to Instrument Valves. Lloyds Register certificate. Parker Hannifin. Instrumentation Products Division.
    • Part one (ISO 15848-1) covers the classification system and qualification procedures for type testing of valves, including grades of temperature, firmness and susceptibility to leakage
    • Part two (ISO 15848-2) covers production acceptance testing of valves that have been approved to ISO 15848-1. This involves a simpler helium sniffer test, carried out at room temperature with five mechanical actuations.

    ISO 15848 defines three leakage classifications that specify maximum leakage rates, with Class A being the most stringent.

    Parker products have been compliant with ISO 15848 for some years now.

    Pic.1. Lloyd’s Register verification for the Pro-Bloc® 15mm process to instrument valves dates back as far as July 2007.

    Verifications and third-party approvals.

    Typical industry procurement practices require certificates of approval or third-party verifications as a condition of supply. Reputable valve manufacturers, including Parker, can provide signed and witnessed certificates - along with verification from industry-leading organisations and technical advisors such as Lloyds, TUV and DNV.

    If verifications are provided by an unknown third party, engineers and procurement specialists may want to satisfy themselves with the quality and level of certification offered - ensuring that any named verifiers are trusted experts in their field. And it’s important that suppliers can provide access to any stated certification, as proof of capability and to ensure practices are up-to-date.

    Reducing Fugitive Emissions - Meeting ISO Standards with Process to Instrument Valves.Shell TAMAP valve. Parker Hannifin. Instrumentation Products Division.Experience supporting major companies and being on approved vendor lists can also be a useful indicator of supply quality. Manufacturers of process to instrument valves who are working with oil majors typically have to pass stringent pre-qualification checks and approval systems. For example, Shell’s robust enterprise framework agreement requires suppliers to:

    • Meet specific codes aligned to ISO 15848, namely SPE 77/300
    • Go through a series of tests (such as testing packing after a specified number of actuations)
    • Complete witness-tested approvals
    • Achieve leading third-party verification.

    Passing these tests is a strong indicator of supplier credentials. Parker is proud to have recently secured a five-year extension to its framework agreement with Shell following a recent factory audit and witness-tested Type Approval Test. The extension was secured due to Shell being satisfied with Parker products and service over the previous five years.

    Pic.2. Parker’s MESC compliant Double Block and Bleed valve.

    Industry expertise and training.

    In offshore applications, the implications of insufficient expertise or training can carry significant risk. It’s therefore imperative that any suppliers demonstrate their understanding of the business environment and relevant operations.

    Asking suppliers for details of their testing practices and procedures, familiarity with legislation and adherence to industry standards will help to build a clear picture of suppliers’ relative experience and credentials.

    Suggested questions for potential suppliers.

    EPC contract engineers and procurers commissioning process to instrument valves may find it helpful to consider the following areas when considering potential suppliers:

    1. Does the supplier have ISO 15848 (part 1 and part 2) signed-off by a leading third-party verifier such as Lloyds, DNV or TUV?
    2. If an unknown verifier has issued approval, has their expertise been confirmed?
    3. What product type(s) do the stated approvals cover? For example: fugitive emissions, ball and needle designs used on double block and bleed and so on.
    4. What other certificates, approvals or verifications can the supplier offer - for example, Type Approval Test certification – and can they supply up-to-date evidence to prove this?
    5. Can the company offer any designs exceeding industry standards?

    To find out more about Parker’s fugitive emission credentials and high-quality process to instrument valves, please visit Parker Instrumentation Products Division website.

     

    Reducing Fugitive Emissions - Meeting ISO Standards with Process to Instrument Valves. Jim Breeze, Flange Products Product Manager, Parker Hannifin, Instrumentation Products Division Europe.Article contributed by Jim Breeze - Flange Products Product Manager at Parker Hannifin, Instrumentation Products Division Europe.

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    Reducing Fugitive Emissions - Meeting ISO Standards with Process to Instrument Valves
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