Cerabar S PMP75 - E+H Level Transmitter Installation

Remember 2 days ago I post about this Endress Hauser Level Sensor Transmitter Cerabar S PMP75? Remember the about the Druck 1830 level sensor transmitter I posted few months ago?

Cerabar S PMP75 - E+H Level Transmitter Installation Work

Cerabar S PMP75 - E+H Level Transmitter Installation Work

Hope you enjoy this entry and and don't forget to come back later. Any comments and suggestions are welcome.

Cerabar S PMP75 - PMP75-ABA1HB8B3AAA CERABAR S DIGITAL PRESSURE TRANSMITTER

Cerabar S PMP75

Cerabar S with metallic measuring diaphragm and diaphragm seal. Overload-resistant and function-monitored. Communication via HART, PROFIBUS PA or FOUNDATION Fieldbus. Areas of application

The Cerabar S pressure transmitter is used for the following measuring tasks:

	Absolute pressure and gauge pressure in gases, steams or liquids in all areas of process engineering and process measurement technology
	Level, volume or mass measurement in liquids
	HIgh process temperature with diaphragm seals up to 350°C (662°F)
	High pressure up to 700 bar This device we replace at the Druck 1830 Level Pressure Sensor Electro Chlorination Plant. In next post, I will enlosed together with the photos during the level sensor installation. More details about this level sensor transmitter: Click here Endress Hauser.

Kelco F25-B Series Corrosive Flow Switch

Kelco F25-B Series Corrosive Flow Switch

This is a new flow switch that we found at market and currently installed at our electrolyser ECP Stream. Alternative to Flotech ECP Flow Switch which give a lot of problems recently.

Anyway, just for your information this kind of switch already used 3 months and the result is very good and no defect from operation at all so far. If this F25-B Series Corrosive Flow Switch can be long lasting live, I would consider this one to replace the old Flotech brand flow switch. At least maybe 1 year... mmmm... what do you think?

Kelco F25-B Series Corrosive Flow Switch at Pipe

Full Specifications are as follow:

F25 SERIES CORROSIVE
RESISTANT FLOW SWITCH
BRAND : KELCO, MODEL : F25-B
DRY RED SWITCH, 240V AC 200V DC 1A

Anyone has use this product before? Please shares here. Thanks...

Crowcon Hydrogen Leakage Detector Monitoring System - Flamgard Exe

Crowcon Hydrogen Sensor - 96HD

Crowcon Hydrogen Panel Rack

Crowcon Hydrogen Panel Display

Crowcon Hydrogen Panel (Back)

Hydrogen is highly explosive gas. All of the 7 Hydrogen detectors in our Electro Chlorination Plant (ECP) are using Crowcon Hydrogen monitoring system.

A situation lead to an extremely dangerous explosive condition if one of the ECP streams were to develop a leak and Hydrogen concentration in the building reached above the Lower Explosive Limit (LEL).

Recommended Action when the alarm appeared:

1. Troubleshoot the reason why the detectors give an alarm. If the detectors are functioning correctly, there should not be any spurious alarms. There would not normally be Hydrogen present in sufficient quantities.
2. Zero the detectors using compressed air and calibrate using a suitable Hydrogen calibration gas.
3. Uninhibit the Hydrogen detection input channels and restore the system to normal operation.

Anyone that using this system facing some problems? Is this equipment Crowcon very reliable at your plant? Post and share here.

Endress+Hauser Electromagnetic Flowmeter Promag 53 Project Update

Promag 53 Transmitter

Promag 53 Recorder and Transmitter

Promag 53 Transmitter Sensor Location

Promag 53 Sensor at the ECP Pipe

Promag 53 Recorder

Yesterday I post about the Endress+Hauser Electromagnetic Flowmeter Promag 53 Project. Now the project still in testing for around 2 weeks. If this success, we will try to install this new model to our Electro Chlorination Plant.

Endress+Hauser Electromagnetic Flowmeter Promag 53

Endress+Hauser Electromagnetic Flowmeter Promag 53

This is a new electromagnetic flowmeter delivered yesterday by Endress+Hauser personal and will be installed at the electrolyser chlorination plant pipe for flow measurement. The consequences of flow switch failure frequently and repeated recently at this electrolyser pipe which cause the Electro Chlorination Plant trip.

This situasion leads to several trial units of many brands to avoid this happen and happen again. Anyway, this one also a trial unit and if the result success will be considered.

Promag 53 Specifications

In this post, I just describe the general information of this product. Later on will include details. So make sure you will not miss my post.

FLOW SWITCH WE ANDERSON FLOWTECH V8 A09P

ITEM: FLOW SWITCH FLOWTECH
MODEL : V8 A09P
MAKER: W.E. ANDERSON
LENGTH OF FLAP: 80MM
POWER SUPPLY: 125/250 VAC, 5 AMP
OUTPUT: 4-20 mA, 2 WIRE

Quantity: 50 Pieces urgently required because the stock is running currently low.

Druck 1830 Level Pressure Sensor at The Sodium Hypochloride Tank

On last Friday, I went around power plant to check some instrumentations. This sodium hypochloride tank actually located behind the ECP and it's a part of the chlorine process. We have two hypochloride tank in our power plant and the tanks are parallel. Meaning that the level should be the same level except the operators close the equalize valve.

PTX 1830 Druck Level Sensor

This is the original level sensor that we have at the hypochloride tank. The range is 10mH2O g. No isolating valve was installed to the level sensor which cause us problem to change during tank in operating.

Foxboro Pressure Transmitter

While this is another option that we used to replace the faulty level sensor. This is only temporary but currently it is also not available or cannot be used because the application is not suitable with strong chlorine which caused the damaged to diaphragm.

I am not so sure about the specification and I will try find it later. So don't forget to come back to know more about this transducer.

Installation of Thermo Fisher SX40 at the Electrochlorination Plant

I took some photos for the new project Water Treatment Plant. This is the photos for the new probes and transmitter installation.

Thermo Fisher Flow Transmitter

The Polyphonics SX40 Probe

Related Articles you may read;
- Trial Instrumentation Field Device at ECP Failed
- ECP Flow Switch Delivered Today
- New Project Flow Switch at ECP
- Electrochlorination Plant Flow Switch

Thermo Fisher Scientific SX40

It is already more than one month after I posting about this simple Flow Switch at the Electrochlorination Plant. Then it failed for a few times which we need to do the repeat order the old flow switch even though it is easily damaged by strong chemical or specifically chlorine. Last week one of OEM parts and specialize about this product do the testing. Currently it has shown positive signal meaning that the thing can work there.

Thermo Fisher Scientific Polysonic SX40

"The Polysonics SX40 is a dedicated Doppler flowmeter which utilizes a patented digital signal processing technique to determine the flow of liquids that contain particulate or air bubbles. The meter incorporates clamp-on sensors which are easily installed for sludge management in sewage treatment plants and industrial applications such as slurry and effluent monitoring."

Product details:

"The Hydra SX40 is designed as a permanently installed flow meter. Its large backlit graphics display provides excellent visibility even in poorly lit environments. As well as flow rate and flow total, a flow trend is available to quickly analyze flow over a period of time. This is especially useful for analyzing pump cycling activity. Standard outputs include 4-20mA, RS232 serial interface and up to four programmable relays. The flow meter also incorporates a 90,000-point data logger."

We will test this product for a whole month to make sure that this kind of new proposal instrumentation or transducer can be worked in the very corrosive environment.

Trial Instrumentation Field Device ECP Flow Switch Chlorine Application Failed

Again, this morning operation raised defect to us on Electro Chlorination Plant (ECP) flow switch problem. After a few days switch has been installed with minor modification on the probe; new spring changed to stainless steel and the flapper is coated with anti-oxide hoping that the lifetime can be longer than before, but the result frustrated. There is already a few times I mentioned in this blog that the unreliable flow switch urgently needs to be replaced as the ECP Cell downtime very frequently happened.

Recently, Vega and Endress Hauser tested their probes on the ultrasonic type. It took one week to complete in January. The tuning of the parameters has been done for a few times to get a good result but at the last stage it failed. The reason it failed is the flow rate is not stable due to two medium mixture, water and air bubbles. In this case, air bubbles will absorb the signal from the ultrasonic then cause the reading fluctuating. At the end, they would like to trial another type of measurement either magnetic or different pressure DP type. But I am still waiting for them to their recommendation which has been promised in February.

I still remember that the current Flotech flow switch that we are using already more than two years. But recently in these 3 to 4 months, the flow switch flapper and the spring brittles and easily broken. Actually this is not the first time we change to a new brand on ECP flow switch. If I am not mistaken, it is already third or fourth times since 2004. So far most of our instrumentation field devices when comes to a new solution doesn’t give us much trouble. Aaarrrgghh… meaning that I have to find out other new brand or new type of flow switch to cut this problem from happens and happens again.

At this moment, I have to contact various manufacturers to recommend the suitable flow switch on the chlorine application which urgently required including ABB, UE and Kelco. Since the stocks balances at the store for the old type (Flotech) are very critical low therefore we need to reorder for temporary used.

ECP Flow Switch Already Delivered Today

If you remember my previous post about this flow switch, the stock already zero at our store. At the moment the ECP Flowtech flow switch give a lot of problem to us.

10 New Pieces ECP Flowtech Flow Switch Delivery in a Box

The root cause of the problem it is always broken or the spring easily drop off because of the chlorine which we know that it's create corrosion. We got 10 pieces. Anyway need to modify to 2.5 inch and put some weightage at the end of the rod. The project to change to the new non-contact sensor still in progress. Will update later.

New Project Flow Switch at Electrochlorination Plant

Remember when I posted about the flow switch before? Now we have a new project to change all the old flow switch type which give us a lot of problem at the electrochlorination plant. The reason why this old type switch need to be change is because our ECP always tripped when the flow switch is broken. The new project actually to change the contact probe to non-contact which might increase the reliabilty of the plant process. I put here some photo for your review.



There are two vendors promoting their product for testing, Vega and Endress Hauser. Both already installed their products and the testing result will be after 1 months installation.

Electrochlorination Plant (ECP) Flow Switch

Called by operation to check ECP no.1 flow switch failed at stream A. From operation feedback, ECP No 1 tripped on no flow on stream A. Operation tried putting ECP No 1 in service early morning today. It could be the following:-

1. Flow switch faulty. Based on our discussion our instrument team (C&I) worked on the flow switch last Saturday.

2. Actual no flow due to wrong isolation, clogging of the inlet pipe, clogging of the outlet pipe.

Permit issued and found switch spring disconnected. Repair the spring and fixing back the switch. Waiting operation to test run. Currently we are lack of this flow switch type and need to reorder. The specification and the photo as below:

Electrochlorination Plant (ECP) Flow Switch

Flotech Flow switch
Model = V8
Supply :125/250 VAC , 5 A
Manufacturer : Dwyer Intruments INC. Michigan City, Indiana, USA