Recent trends in multi-sensor measurements within a mass flow controller are reviewed, with a focus on controller self-diagnostics.
While the quality, reliability, accuracy, response and range of MFCs continues to improve year after year, the process is still at risk because meaningful real-time in situ data is limited or nonexistent.
Failure Analysis of Feedstock Preheater Unit of the Kaduna Refinery using Fai...theijes
The use of failure modes effects and criticality analysis (FMECA) as a failure or reliability analysis tool, checks the probabilities that an item will perform a required function under stated condition(s) when operated properly.Failure analysis of process equipment is an important issue in any process industry. This study aims at analyzing the failure of feedstock preheater unit of the Kaduna Refining and Petrochemicals (KRPC), Fluid Catalytic Cracking Unit (FCCU), using the failure mode, effects and criticality analysis (FMECA). The unit failure and its effects were identified through seven sub-units (fresh feed surge drum, heavy naphtha exchanger, light cycle oil exchanger, heavy cycle oil exchanger, fractionator bottom exchanger, feed preheater and fresh feed charge pump), using the failure mode effects analysis (FMEA). Both quantitative and qualitative criticality analyses (CA) were used for failure analysis of the unit (feedstock preheater). For the qualitative analysis, items risk priority number (RPN) were computed and it was found that, four sub-units (heavy naphtha exchanger, main fractionator bottom exchanger, feedstock preheater, and fresh feed charge pump) had their Risk Priority Number (RPN) greater than 200, these sub-units are said to be critical. Three of the sub-units (fresh feed surge drum, light cycle oil exchanger, and heavy cycle oil exchanger) had their RPN less than 200, these sub-units are said to be less critical. For the quantitative analysis, items criticality number (Cr) were computed and it was found that most of the sub-units had their Cr>0.002. In addition, the results of the criticality matrix showed that, eight out of the sixteen failure modes identified were above or closely below the criticality line. Finally, FMECA was effectively used for failure analysis of the feedstock preheater andpredictive maintenance was recommended.
The Variable Area Flowmeter is an instrument for measuring the flow of liquids and gases in pipelines. It includes a vertical tube through which the fluid flows whose diameter increases from the bottom to the top and a float which can move vertically in the tube.
As the flow increases this float moves to a higher position until its resistance to the fluid flow is balanced by the float’s buoyed weight in the fluid, a value which is constant and independent of the flowrate.
The position of the float is a measure of the flowrate. The flowrate values can be read on a scale.
Failure Analysis of Feedstock Preheater Unit of the Kaduna Refinery using Fai...theijes
The use of failure modes effects and criticality analysis (FMECA) as a failure or reliability analysis tool, checks the probabilities that an item will perform a required function under stated condition(s) when operated properly.Failure analysis of process equipment is an important issue in any process industry. This study aims at analyzing the failure of feedstock preheater unit of the Kaduna Refining and Petrochemicals (KRPC), Fluid Catalytic Cracking Unit (FCCU), using the failure mode, effects and criticality analysis (FMECA). The unit failure and its effects were identified through seven sub-units (fresh feed surge drum, heavy naphtha exchanger, light cycle oil exchanger, heavy cycle oil exchanger, fractionator bottom exchanger, feed preheater and fresh feed charge pump), using the failure mode effects analysis (FMEA). Both quantitative and qualitative criticality analyses (CA) were used for failure analysis of the unit (feedstock preheater). For the qualitative analysis, items risk priority number (RPN) were computed and it was found that, four sub-units (heavy naphtha exchanger, main fractionator bottom exchanger, feedstock preheater, and fresh feed charge pump) had their Risk Priority Number (RPN) greater than 200, these sub-units are said to be critical. Three of the sub-units (fresh feed surge drum, light cycle oil exchanger, and heavy cycle oil exchanger) had their RPN less than 200, these sub-units are said to be less critical. For the quantitative analysis, items criticality number (Cr) were computed and it was found that most of the sub-units had their Cr>0.002. In addition, the results of the criticality matrix showed that, eight out of the sixteen failure modes identified were above or closely below the criticality line. Finally, FMECA was effectively used for failure analysis of the feedstock preheater andpredictive maintenance was recommended.
The Variable Area Flowmeter is an instrument for measuring the flow of liquids and gases in pipelines. It includes a vertical tube through which the fluid flows whose diameter increases from the bottom to the top and a float which can move vertically in the tube.
As the flow increases this float moves to a higher position until its resistance to the fluid flow is balanced by the float’s buoyed weight in the fluid, a value which is constant and independent of the flowrate.
The position of the float is a measure of the flowrate. The flowrate values can be read on a scale.
Drager PointGard 2000 Series Gas Detection SystemFlow-Tech, Inc.
The Drager PointGard® 2000 series is a self-contained gas detection system for the continuous area monitoring of toxic or flammable gases in ambient air. PointGard® 2000’s rugged, water-resistant enclosure comes complete with a horn and strobes, a built-in power supply, and reliable DragerSensor®.
Thermal dispersion switch for flow, level, interface, or temperatureFlow-Tech, Inc.
FCI liquid level/interface switches feature thermal dispersion technology in which the temperature difference between the two RTDs is greatest in the absence of liquid and decreases when the level element is submerged, cooling the heated RTD.
FCI flow switches feature thermal dispersion technology in which the temperature difference is greatest in a no-flow condition and decreases as flow increases, cooling the heated RTD. Changes in flow velocity directly affect the extent to which heat dissipates and, in turn, the magnitude of the temperature difference between the RTDs.
GE Advanced Modular Calibrator for Process Measurement InstrumentsFlow-Tech, Inc.
The DPI 620 Genii is an easy to use, rugged, and highly accurate multifunction instrument for calibrating & maintaining process instrumentation. Its modular design and functionality means it can be expanded over time and tailored to applications as needs change. With options that include HART / Fieldbus / Profibus communications, it’s a powerful, simple to use and high accuracy calibrator.
Siemens power cell design allows for less maintenance and greater availability. And when combined with up to 90% savings on cable costs, the result is a significantly lower total cost of ownership over the drive’s lifecycle. No other drive offers the savings and reliability that the SINAMICS PERFECT HARMONY GH180 does, making it the ideal solution for low power applications
Scenarios for Specifying an Uninterruptible Power Supply for Industrial Appli...Classic Controls, Inc.
For a number of years, some industries have used UPSs as a matter of course in applications requiring
uninterrupted process control. These include power-generation facilities, both fossil and nuclear, and petrochemical
plants and refineries.
Recently, other types of industrial companies (pulp and paper mills, steel mills, pharmaceutical manufacturing and
cogeneration facilities) have created a need for UPSs by incorporating DCSs into their plants to control their
processes. Additional control equipment, such as supervisory control and data acquisition (SCADA) systems,
energy management systems (EMSs), boiler-control and microprocessor-based instrumentation, give power
protection an even more important role in industry.
The Model 212 Heat Calculator is designed to measure the energy consumed in both heating and cooling (air conditioning) systems. The instrument is normally supplied complete with temperature probes and power supply, and will interface to a wide variety of flowmeters, including positive displacement and inferential water meters, magnetic flowmeters with pulse outputs, turbine flowmeters &
paddlewheel flowmeters.
The Model 212 measures the temperature in the feed and return flow lines and uses this information to calculate the density and enthalpy of water. By also measuring the volume of water flowing in the system, the Model 212 will then determine the energy used.
Eurotherm manufactures temperature sensors, process controllers, power controls, SSR, SCR, and thermowells for process temperature measurement and control. This product guide summarizes the company's US product offering.
CO2 Incubator is designed and manufactured using the accumulated expertise and knowledge that Esco has developed with over 35 years of world class equipment for laboratory usage. Designed with sample safety, energy efficiency and user-friendliness in mind, the system achieves precise parameter controls, highly effective contamination control and intuitive user interfaces all--supported by Esco's solution-based sales and service representatives worldwide.
The cast stainless steel mounting bracket facilities the installation of Westlock Control's control valve monitors on any actuator with the standard NAMUR mounting patterns.
The T2750 PAC hardware provides high-performance control with cost-effective redundancy options in a versatile modular system. Powerful instruments, the control units, and the I/O system form the basis of a complete distributed control and recording environment. This environment is capable of continuous analog, logic, sequential control, batch management, secure data recording at point of measurement, and setpoint programming.
Drager PointGard 2000 Series Gas Detection SystemFlow-Tech, Inc.
The Drager PointGard® 2000 series is a self-contained gas detection system for the continuous area monitoring of toxic or flammable gases in ambient air. PointGard® 2000’s rugged, water-resistant enclosure comes complete with a horn and strobes, a built-in power supply, and reliable DragerSensor®.
Thermal dispersion switch for flow, level, interface, or temperatureFlow-Tech, Inc.
FCI liquid level/interface switches feature thermal dispersion technology in which the temperature difference between the two RTDs is greatest in the absence of liquid and decreases when the level element is submerged, cooling the heated RTD.
FCI flow switches feature thermal dispersion technology in which the temperature difference is greatest in a no-flow condition and decreases as flow increases, cooling the heated RTD. Changes in flow velocity directly affect the extent to which heat dissipates and, in turn, the magnitude of the temperature difference between the RTDs.
GE Advanced Modular Calibrator for Process Measurement InstrumentsFlow-Tech, Inc.
The DPI 620 Genii is an easy to use, rugged, and highly accurate multifunction instrument for calibrating & maintaining process instrumentation. Its modular design and functionality means it can be expanded over time and tailored to applications as needs change. With options that include HART / Fieldbus / Profibus communications, it’s a powerful, simple to use and high accuracy calibrator.
Siemens power cell design allows for less maintenance and greater availability. And when combined with up to 90% savings on cable costs, the result is a significantly lower total cost of ownership over the drive’s lifecycle. No other drive offers the savings and reliability that the SINAMICS PERFECT HARMONY GH180 does, making it the ideal solution for low power applications
Scenarios for Specifying an Uninterruptible Power Supply for Industrial Appli...Classic Controls, Inc.
For a number of years, some industries have used UPSs as a matter of course in applications requiring
uninterrupted process control. These include power-generation facilities, both fossil and nuclear, and petrochemical
plants and refineries.
Recently, other types of industrial companies (pulp and paper mills, steel mills, pharmaceutical manufacturing and
cogeneration facilities) have created a need for UPSs by incorporating DCSs into their plants to control their
processes. Additional control equipment, such as supervisory control and data acquisition (SCADA) systems,
energy management systems (EMSs), boiler-control and microprocessor-based instrumentation, give power
protection an even more important role in industry.
The Model 212 Heat Calculator is designed to measure the energy consumed in both heating and cooling (air conditioning) systems. The instrument is normally supplied complete with temperature probes and power supply, and will interface to a wide variety of flowmeters, including positive displacement and inferential water meters, magnetic flowmeters with pulse outputs, turbine flowmeters &
paddlewheel flowmeters.
The Model 212 measures the temperature in the feed and return flow lines and uses this information to calculate the density and enthalpy of water. By also measuring the volume of water flowing in the system, the Model 212 will then determine the energy used.
Eurotherm manufactures temperature sensors, process controllers, power controls, SSR, SCR, and thermowells for process temperature measurement and control. This product guide summarizes the company's US product offering.
CO2 Incubator is designed and manufactured using the accumulated expertise and knowledge that Esco has developed with over 35 years of world class equipment for laboratory usage. Designed with sample safety, energy efficiency and user-friendliness in mind, the system achieves precise parameter controls, highly effective contamination control and intuitive user interfaces all--supported by Esco's solution-based sales and service representatives worldwide.
The cast stainless steel mounting bracket facilities the installation of Westlock Control's control valve monitors on any actuator with the standard NAMUR mounting patterns.
The T2750 PAC hardware provides high-performance control with cost-effective redundancy options in a versatile modular system. Powerful instruments, the control units, and the I/O system form the basis of a complete distributed control and recording environment. This environment is capable of continuous analog, logic, sequential control, batch management, secure data recording at point of measurement, and setpoint programming.
Uniquely engineered load cells that are designed to maximize accuracy and minimize the effects of mixing, agitation and temperature changes in critical process weighing stages. Its signal conditioners and process control systems are designed to comply with the stringent requirements of the chemical, steel, food and pharmaceutical industries, and offer a wide variety of communication protocols used in complex production lines.
Industrial Wireless Network Components and EquipmentArjay Automation
A broad range of industrial wireless products delivers comprehensive solutions for reaching network devices, streamlining operations, improving productivity and safety, and reducing overall cost.
Moore Industries is proud to announce the new SFY Functional Safety Frequency-to-DC Transmitter with display including SIL 3 capability. The 2-wire (loop-powered) SFY is ideal for use in your Safety Instrumented System (SIS) in a wide range of process and factory automation monitoring applications and as part of the FS Functional Safety Series providing reliable and accurate monitoring of frequency or pulse signals in SIS. The SFY is approved for single use in SIS up to SIL 2 and in a redundant architecture (1oo2, 2oo3, etc.) up to SIL 3.
Laboratory animal cage washing has traditionally employed very hot rinse or wash water to assure the destruction of microbial agents which can cause disease in laboratory animals. This study shows an alternative that may conserve substantial amounts of energy and still provide suitable results.
High performance differential pressure transmitters feature a single crystal silicon resonant sensor and are suitable to measure liquid, gas, or steam flow as well as liquid level, density and
pressure. Standard output is a 4 to 20 mA DC signal corresponding to the measured differential pressure. Its highly accurate and stable sensor can also measure the static pressure which can be shown on the integral indicator or remotely monitored via BRAIN or HART communications.
Induction heating can improve your bottom line by decreasing weld failures, and decreasing setup and tear down times. The technology allows for accurate temp control, without heavy electrical service or complicated controls. The portability and ease of use will allow you to heat more welds faster.
Excellent paper on cavitation in control valves by Samson. Read this for a strong technical understanding of the cause and effects of cavitation and flashing on industrial control valves.
Cavitation shall be generally understood as the dynamic process of the formation and implosion of cavities in fluids.Cavitation occurs, for instance, when high flow velocities cause the local hydrostatic pressure to drop to a critical value which roughly corresponds to the vapor pressure of the fluid. This causes small bubbles filled with steam and gases to form. These bubbles finally collapse when they reach the high-pressure areas as they are carried along by the liquid flow. In the final phase of bubble implosion, high pressure peaks are generated inside the bubbles and in their immediate surroundings. These pressure peaks lead to mechanical vibrations, noise and material erosion of surfaces in walled areas. If cavitation is severe, the hydraulic valve coefficients as well as the fluid properties change.
The Unisteri HP is a unique, compact, multipurpose steam sterilizer with chamber volumes of 2.5 ft3, 5.6 ft3 and 8.47 ft3 (73, 160 and 254 liters). It is designed to effectively sterilize all instrumentation, materials, textiles, rubber and plastics that are heat resistant. It is also suitable for media cultivation and sterilization of solutions.
One of the most widely used methods of monitoring and controlling liquid level in a tank is the use of Bubble Tubes with Pressure or Differential Pressure Transmitters. A small but uninterrupted flow of air or inert gas is forced down through a dip tube which extends to near the bottom of the tank. The back pressure of the introduced gas is a function of the liquid level or head in the tank.
Detection system design of subsea tree controllerIJCSES Journal
To meet the requirements of the detection system of underwater controller of subsea tree, this paper adopts
the data acquisition and control mode of “HMI+ SIEMENS PLC+SQL ".Using the configuration software,
completed the development and design of production tree detection system to monitor, control and data
communication. The monitoring function has realized the process simulation of oil tree, the control
function has realized the remote control of oil tree, and database SQL has realized the management and
analysis of data in oil well, achieving real-time tracking, rapid response, improve speed , quality and
reporting level of oil production engineering design .At the same time the design center can make full use
of the database to complete the design of required query, statistical analysis and the output function of
related form .
Turbine flowmeters utilize a proven flow measurement technology to provide exceptionally accurate and reliable digital outputs. Because of their versatility, these turbine flowmeters are the solution for a wide variety of liquid and gas flow sensing applications. Turbine meters are an ideal solution when high accuracy, compact size, fast response, and high tolerance to shock and vibration are critical requirements.
Effect of Different Defuzzification methods in a Fuzzy Based Liquid Flow cont...IJITCA Journal
Most of the process control technique is suffered by the complex dynamic systems with nonlinear or timevariable thats why it is very difficult to describe the behaviour of the system. One way to deal with the
uncertainty of the behaviour of the system is to use fuzzy logic.If Fuzzy logic was modelled on spontaneous human reasoning then it captures the impreciseness the most input data which are inherent. In a fuzzy logic controller the focus is the human operator's behaviour, whereas in conventional PID controller what is modeled is the system or process being controlled.FLC regulator has a very good result from complex
nonlinear dynamic processes, uses the reasoning of the human mind which is not always in the form of a
yes or no. In this work,it shows overall effective control and operation of the mechanical equipments applied for control of liquid flow, implemented the fuzzy liquid flow algorithm and compared the effect of
using different defuzzification methods.Flow control system takes information about sensor output voltage,
control valve opening & flows rate as parameters and controls in case of overflowing & wastage.In this design two input parameters: sensor output voltage and rate of change voltage and one output parameters: opening of the control valve .
Effect of Different Defuzzification methods in a Fuzzy Based Liquid Flow cont...IJITCA Journal
Most of the process control technique is suffered by the complex dynamic systems with nonlinear or timevariable
thats why it is very difficult to describe the behaviour of the system. One way to deal with the
uncertainty of the behaviour of the system is to use fuzzy logic.If Fuzzy logic was modelled on spontaneous
human reasoning then it captures the impreciseness the most input data which are inherent. In a fuzzy logic
controller the focus is the human operator's behaviour, whereas in conventional PID controller what is
modeled is the system or process being controlled.FLC regulator has a very good result from complex
nonlinear dynamic processes, uses the reasoning of the human mind which is not always in the form of a
yes or no. In this work,it shows overall effective control and operation of the mechanical equipments
applied for control of liquid flow, implemented the fuzzy liquid flow algorithm and compared the effect of
using different defuzzification methods.Flow control system takes information about sensor output voltage,
control valve opening & flows rate as parameters and controls in case of overflowing & wastage.In this
design two input parameters: sensor output voltage and rate of change voltage and one output
parameters: opening of the control valve .
Instrumentation, SCADA, LIMS: Tools for efficient management the operational ...ISA Interchange
Sanitation plants generally involve low rates of automation, especially in Brazil. This review article
makes an attempt to change this scenario by demonstrating the importance of the automation of
these plants. This article describes the efficient operation of a plan submitted for the automated
control systems of a Water and Sanitation Company. Several properties and issues are observed
during the execution of the project. The properties observed include the integration of automation
systems, instrumentation, PLC (Programmable Logic Controller), SCADA (Supervisory Control
and Data Acquisition) and LIMS (Laboratory Information Management Systems). On the other
hand, issues observed include the lack of precision in the processing of data, difficulty in system
integration and security issues among other things. The aim of this paper is to analyze the
importance of process measurement and control in the operational management of the Company.
The results indicate that the use of measurement and control systems leads to improved quality of
processes and laboratory data. This study suggests technological tools to monitor the specific
parameters of the process and presents network topology automation telemetry currently in use for
executing critical analyses of the topology and security policy information employed in this
environment. It describes and analyzes the automation project, from implementation issues,
including justification, to aspects concerning purchasing and validation. Furthermore, it details
benefits of automation, such as standardization of technology, economies of scale, time savings,
increased productivity, reduced errors, increased reliability of results and the available and
accessible production of knowledge, thus transforming it into a tool for decision making.
[Oil & Gas White Paper] Getting Ahead of the Game: adopting best practices in...Schneider Electric
Burgeoning energy exploration is driving the construction of pipeline systems for hydrocarbon transportation. For a variety of reasons, including renewed scrutiny on safety by regulators, this is also driving new practices and standards for leak detection.
Computational pipeline monitoring (CPM) systems use real-time information from the field – such as pressure, temperature, viscosity, density, flow rate, product sonic velocity and product interface locations – to estimate the hydraulic behavior of the product being transported and create a computerized simulation. With it, controllers can be alerted to abnormal operating conditions that might signal the existence of a pipeline leak. Different CPM methodologies provide different leak detection capabilities, so different methods, or a combination of methods, might be better applied to different operations.
Selection of the right CPM for a given company or given pipeline relies on the thorough evaluation of several factors, including pipeline characteristics, business objectives, additional risk factors and special safety concerns, such as proximity to environmentally sensitive or urban areas. New standards and industry initiatives provide tools to assist in this evaluation, ensuring the pipeline industry continues to provide efficient, effective and safe hydrocarbon transportation.
There are four main considerations to evaluate in order to specify a Thermal Mass Flow Controller (MFC) for your application. Flow range, gas conditions, desired accuracy, and communications are all important constraints. There are a five additional considerations including interior finish for high and ultra high purity applications, materials used in the flow path, the environment such as installations near furnaces or some sort of NEMA rating, mounting attitude such as vertical flow up, and serviceability.
THE PRESSURE SIGNAL CALIBRATION TECHNOLOGY OF THE COMPREHENSIVE TEST SYSTEMieijjournal1
The pressure signal calibration technology of the comprehensive test system which involved pressure
sensors was studied in this paper. The melioration of pressure signal calibration methods was elaborated.
Compared with the calibration methods in the lab and after analyzing the relevant problems,the
calibration technology online was achieved. The test datum and reasons of measuring error analyzed,the
uncertainty evaluation was given and then this calibration method was proved to be feasible and accurate.
THE PRESSURE SIGNAL CALIBRATION TECHNOLOGY OF THE COMPREHENSIVE TEST SYSTEMieijjournal
The pressure signal calibration technology of the comprehensive test system which involved pressure
sensors was studied in this paper. The melioration of pressure signal calibration methods was elaborated.
Compared with the calibration methods in the lab and after analyzing the relevant problems,the
calibration technology online was achieved. The test datum and reasons of measuring error analyzed,the
uncertainty evaluation was given and then this calibration method was proved to be feasible and accurate.
[Oil & Gas White Paper] Liquids Pipeline Leak Detection and Simulation TrainingSchneider Electric
Increasingly, pipeline operating companies must deal with regulations that focus on environmental protection. The goal of the regulations is to minimize pipeline leaks that not only endanger the environment but also result in operator downtime and financial penalties. Identifying, verifying and responding to the abnormal conditions around a potential leak require best practices, including controller training.
A computational pipeline monitoring (CPM) system uses real-time information from the field – such as pressure, temperature, viscosity, density, flow rate, product sonic velocity and product interface locations – to estimate the hydraulic behavior of the product being transported and create a computerized simulation. With it, controllers can be alerted to actual operating conditions that are not consistent with the calculated conditions and might signal the existence of a pipeline leak. Different CPM methodologies provide different leak detection capabilities, so different methods, or a combination of methods, might be better applied to different operations.
A comprehensive CPM system also supports training best practices that help engineers and controllers develop intimate knowledge of the control system interface, alarming functions and response actions. It is an efficient way to implement refresher training to cover network modifications and expansions and to accurately document training, testing results and qualifications. Computerized simulation has demonstrated to provide more comprehensive and effective training for a specific pipeline than on-the-job training. For this reason, it is the preferred method of the U.S. Department of Transportation’s Pipeline Hazardous Materials Safety Association (DOT-PHMSA) for training controllers to recognize the abnormal conditions that might suggest a leak and to optimize the safety of the pipeline operation.
Schneider Electric’s SimSuite Pipeline solution is based on a real-time transient model that includes leak detection capabilities, crucial to safety and environmental concerns; a simulation trainer application for targeted and effective training of operational staff; and forecasting and planning functionalities that help improve business intelligence. Together, these capabilities help the pipeline operator reduce operations cost as well as comply with regulations.
THE PRESSURE SIGNAL CALIBRATION TECHNOLOGY OF THE COMPREHENSIVE TEST SYSTEMieijjournal
The pressure signal calibration technology of the comprehensive test system which involved pressure
sensors was studied in this paper. The melioration of pressure signal calibration methods was elaborated.
Compared with the calibration methods in the lab and after analyzing the relevant problems,the
calibration technology online was achieved. The test datum and reasons of measuring error analyzed,the
uncertainty evaluation was given and then this calibration method was proved to be feasible and accurate.
Numerical analysis for two phase flow distribution headers in heat exchangerseSAT Journals
Abstract A flow header having number of multiple small branch pipes are commonly used in heat exchangers and boilers. In beginning the headers were designed based on the assumption that the fluid distribute equally to all lateral pipes. In practical situation the flow is not uniform and equal in all lateral pipes. Mal distribution of flow in heat exchangers significantly affects their performance. Non-uniform flow distribution from header to the branch pipes in a flow system will lead to 25% decrease in effectiveness of a cross flow heat exchanger. Mal distribution of flow in the header is influenced by the geometric parameters and operating conditions of the header. In this work the flow distribution among the branch pipes of dividing flow header system is analyzed for two phase flow condition. In the two phase flow condition, the effect of change in geometric cross sectional shape of the header (circular, square), inlet flow velocities are varied to find the flow mal distribution through the lateral pipes are investigated with the use of Computational Fluid Dynamics software. Keywords: circular, square headers and Computational Fluid Dynamics software. (CFD)
Similar to New Class of MFCs with Embedded Flow Diagnostics (20)
GE's Bently Nevada 3500 Monitoring System provides continuous, online monitoring suitable for machinery protection and asset condition monitoring applications. It represents their most capable and flexible system in a traditional rack-based design and offers numerous features and advantages not provided in other systems.
Brooks Instrument Series GF40 Installation and Operation ManualFlow-Tech, Inc.
Based upon Brooks award-winning GF100 Series, the GF40 Series is a performance/value MFC platform designed for OEM applications, delivering the following class leading features:
• MultiFloTM process gas and flow range programmability, enabling customers to re-configure the MFC for new gases and full scale flow rates for unparalleled process flexibility.
• A high-performance, corrosion-resistant flow measurement sensor delivers improved reproducibility and stability.
• A variety of elastomer options enable customers to select the optimum and most cost effective mix of products for their application.
• Full range of industrial communication protocols (DeviceNet, Profibus DP-V1, and EtherCAT).
• An independent service/diagnostic port enables on-tool reconfiguration/ optimization, data logging, and troubleshooting without having to remove the MFC from the gas line.
Solving Critical Process Applications for the Water and Wastewater IndustryFlow-Tech, Inc.
Fluid Components International recognized the need for flow and level instrumentation which met specific customer requirements and demands for the Water and Wastewater Industry. By utilizing Thermal Dispersion and Coriolis technology exclusively in all FCI flow, level, interface, temperature switches and mass flow meters, our products solve typical Water and Wastewater Industry application challenges with standard product features.
Precise and easy non-invasive ultrasonic thermal energy measurement. District heating and cooling, Combined heat and power (CHP), Heating plants, Chiller plants, Sub-metering, Energy optimization, Leak Detection, Energy performance of buildings, Energy Audits, Energy Management System
Yokogawa, globally recognized leader in a number of process control fields, has authored an e-book which provides useful insight into how operators of combustion based equipment and systems can improve efficiency and enhance safety by employing modern technology.
Turbine flow meters for gas service from HofferFlow-Tech, Inc.
Hoffer Flow Controls manufactures high precision turbine flowmeters for the cryogenic industry and is the world leader in turbine flowmeter technology for the measurement of clean liquids and gases throughout the processing industries.
The FLUXUS G601 CA Energy is the ideal tool for carrying out complete energy efficiency tasks in the industry as well as within facility management (e.g. according to DIN ISO 50001 standards) by allowing the measurement of compressed air flow rates as well as the monitoring of thermal energy quantities and the flow rate determination of any kind of liquid or gaseous media with just one device.
Improve Process Control Security Using Annunciators as WatchersFlow-Tech, Inc.
Software-based systems are vulnerable to cyber attacks. Most of the industrial control networks (CAN, PROFI, Control Area, Ethernet and RS485) connect to the internet or other computer networks which are not fully protected from hackers and viruses. Present day industrial DCS/PLC control systems come with redun- dancy systems to eliminate shutdowns in case of DCS/PLC hardware failures. However, this does not protect your DCS/PLC system from any type of cyber attack. Without proper protection, the safety and/or operation of your plant or business are put at great risk.
Engineers with small line size processes rely on the versatile Wafer-Cone Flow Meter for superior accuracy and repeatability. The space-saving unit is easy to install. It’s ideal for tight-space installations and retrofits.
The flangeless Wafer-Cone® is compact, less costly and easy to install. The cone conditions the flow so the Wafer-Cone requires minimal upstream or downstream pipe runs and can be installed virtually anywhere in a piping system. Ideal for small line sizes and with no moving parts, no replacement parts or scheduled maintenance, this meter offers a low cost of ownership and long life.
Reduce Unplanned Outages and Improve Profitability with Asset Condition Monit...Flow-Tech, Inc.
Continuously monitoring critical asset parameters such as vibration, temperature, speed, and numerous other condition indicators is a proven method for anticipating and preventing mechanical failures—proven in tens of thousands of industrial facilities around the world by delivering tangible benefits
List of Detectable Gasses and Vapors by CAS-Number 2015Flow-Tech, Inc.
The CAS-number is a worldwide used code to identify a chemical substance non-ambiguously. This number is issued by the Chemical Abstracts Service and is the easiest way to characterize a chemical substance. Knowing the CAS-No. means to be able to get comprehensive information and links from internet and search engines.
McCrometer V Cone Flowmeter Installation, Operations, MaintenaceFlow-Tech, Inc.
The McCrometer V-Cone® Flowmeter is a patented technology that accurately measures ow over a wide range of Reynolds numbers, under all kinds of conditions and for a variety of fluids. It operates on the same physical principle as other differential pressure-type flowmeters, using the theorem of conservation of energy in fluid flow through a pipe. The V-Cone’s remarkable performance characteristics, however, are the result of its unique design. It features a centrally-located cone inside the tube. The cone interacts with the fluid flow, reshaping the fluid’s velocity profile and creating a region of lower pressure immediately downstream of itself. The pressure difference, exhibited between the static line pressure and the low pressure created downstream of the cone, can be measured via two pressure sensing taps. One tap is placed slightly upstream of the cone, the other is located in the downstream face of the cone itself. The pressure difference can then be incorporated into a derivation of the Bernoulli equation to determine the fluid flow rate. The cone’s central position in the line optimizes the velocity profile of the flow at the point of measurement, assuring highly accurate, reliable flow measurement regardless of the condition of the flow upstream of the meter.
Multivariable Transmitter for Mass Flow MeasurementFlow-Tech, Inc.
The EJX-A series is Yokogawa's premium performance line of DPharp transmitters. Field tested for over 10 years with the performance and stability demanded by industrial process control applications. The EJX910A multivariable transmitter is a remarkable innovation in multi-sensing technology. It makes optimal use of the unique characteristics of Yokogawa's DPharp sensor to provide best in class process measurement performance.
Suitable for all technical levels, this second of three parts continues the explanation of how electrical grounding works, the functions it performs in insuring safety and proper device or equipment operation, and why it is important.
The Brooks family of extremely high-performing direct liquid injection (DLI) vaporizer solutions is designed for customers who require reliable liquid vaporization. Featuring unique atomization and heat exchanger technologies, Brooks direct liquid injection vaporizers deliver pure vapor for every application.
1. What is arc flash
2. OSHA, NFPA 70E
3. Codes and standards
4. Protective clothing and equipment
5. Prevention
An arc flash (or arc blast) is a type of electrical explosion that results from a low impedance connection to ground or another voltage phase in an electrical system
Even without electrocution, death or dismemberment may occur through an intense arc blast, up to 35,000 F deg, and force up to 2100 psi from the intense heat rapidly expanding the air, copper & particles creating a shockwave blast. Droplets of molten metal and shrapnel can penetrate the body.
A review on techniques and modelling methodologies used for checking electrom...nooriasukmaningtyas
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Fundamentals of Electric Drives and its applications.pptx
New Class of MFCs with Embedded Flow Diagnostics
1. A New Class of MFCs with
Embedded Flow Diagnostics
WHITE PAPER
www.BrooksInstrument.com WP-A New Class of MFCs with Embedded Flow Diagnostics
June 2016
Bill Valentine is chief technology officer at Brooks Instrument, operating from the company’s
Technology Development Center in Tustin, CA. Shaun Pewsey is a business development
director at Brooks Instrument, Hatfield PA
Mass Flow Controllers
WILLIAM VALENTINE and SHAUN PEWSEY, Brooks Instrument, Hatfield, PA
Recent trends in multi-sensor measurements within a mass flow controller are
reviewed, with a focus on controller self-diagnostics.
Sub 20nm nodes and complex 3D architecture are driving new
process control challenges. In regards to gas delivery, these
complex and highly sensitive processes require mass flow
controllers (MFCs) to provide better accuracy, repeatability, long
term stability and consistent dynamic response. In addition,
foundries are driving a need for greater process and equipment
flexibility which means the MFC must meet demanding process
requirements across a wider control range.
While the quality, reliability, accuracy, response and range of
MFCs continues to improve year after year, the process is still
at risk because meaningful real-time in situ data is limited or
nonexistent. Consequently, an error in delivered flow that is
substantial enough to cause yield and scrap issues would go
undetected until the next off-line flow check.
In situ data traditionally has been limited to detecting obvious
hard failures such as an MFC that is not communicating; the
flow output doesn’t meet the set point; or the MFC output
at a zero set point is offset (not zero). A zero offset will cause
a change in flow accuracy if it is due to an active change in
the zero reference of the flow meter. However, zero offsets
recorded during a process can also be caused by an MFC valve
leak or even an isolation valve leak. A few fault detection and
clarification (FDC) systems attempt to trend valve voltage but
hysteresis of up to 40 percent of a reading means that only
obvious failures can be detected.
In lieu of in situ flow data, flow tests are performed off-line
using a technique such as chamber rate of rise (ROR). The ROR
technique is simply to evacuate a known volume, flow gas into it
and measure pressure change. With chamber ROR, the known
volume is the processing chamber. The chamber is taken off-line
(not running a process) and the MFC is given a flow set point.
As gas flows into the constant volume chamber, the chamber
pressure rises at a constant rate. Flow can be calculated using
the gas law as shown in FIGURE 1. Off-line testing reduces tool
availability and can only detect flow errors after the fact, placing
wafer lots at risk. Chamber ROR accuracy is +/- 3 percent of
reading to +/- 5 percent of reading, depending on flow rate, gas
properties, temperature gradients, manometer accuracy and
chamber outgassing. Even if a better flow standard is available,
flow tests are time-consuming. Chamber ROR testing every
MFC at only one set point on a four-chamber etch tool can take
12 hours and is typically performed weekly.
FIGURE 1. Rate of Rise (ROR) measurement technique
2. Process engineers are seeking an in situ flow verification process
to ensure process repeatability enabling real-time FDC to
alarm on conditions that could lead to wafer scrap. In situ flow
data could also be used to intelligently determine when to
take a tool down for flow verification tests instead of running
time-consuming weekly flow maintenance checks on all MFCs.
The evolution of the MFC
In 2004, MFC manufacturers developed pressure transient
insensitive (PTI) MFCs. Pressure sensors were added to measure
fluctuations in pressure and advanced control concepts were
introduced to compensate for pressure fluctuations in real time.
Recently, several manufacturers have experimented with using
pressure and temperature signals available in PTI MFCs to
determine if the controller accuracy is degrading. (The authors
have used the phrase “multi-sensor diagnostics” to describe
this new class of advanced MFCs). Every multi-sensor diagnostic
technique involves some form of pressure rate of decay (ROD).
ROD is similar to chamber ROR exe. Chcept instead of flowing
into a constant volume and measuring the pressure rise, flow
is released from a constant volume and the rate of pressure
decay is measured. The concept has been around for 30 years
and involves shutting off an upstream valve to create a constant
volume and measuring the pressure drop within the volume. The
technique wasn’t practical until digital processors with enough
computational power were available to perform the technique.
Multi-sensor diagnostic instrumentation can be broken into two
groups. The first group (idle self-diagnostic) can only perform
self-diagnostics while the tool is idle or in between process
steps. Pressure decay in the volume is measured but there is
no attempt to control flow. The signature of the pressure drop
is compared to a previous measurement and analyzed to look
for changes. While considered an improvement, this technique
does not provide true in situ data and a dynamic event during
a process could easily go undetected. The second group
(active self-diagnostic) actively controls process steps while the
pressure decay is measured. Although more challenging to
implement, this technique enables true in situ flow verification
(FIGURE 2).
Examples of idle self-diagnostics
Example 1 - thermal MFC: The upstream isolation valve is
closed and the position of the flow control valve is frozen. The
MFC then records pressure decay. The characteristics of the
pressure decay curve are compared to a baseline curvanges in
the curve are trended to determine if a flow sensor is degrading
(FIGURE 3). Special maintenance checks would have to be
programed into the tool controller to take advantage of this
technique as it cannot be triggered during a normal process run.
FIGURE 3. Thermal MFC Idle self-diagnostics.
FIGURE 2. Comparison of idle and active self-diagnostic during
wafer processing.
WP-A New Class of MFCs with Embedded Flow Diagnostics
June 2016
3. Example 2 - pressure-based MFC: Traditional pressure-based
MFCs measure pressure drop across a laminar flow element
(LFE) (FIGURE 4). The valve must be placed upstream for two
reasons. First, the pressure measurement is more accurate and
stable if P2 is vacuum; second, this method requires a stable
inlet pressure, P1. The downside to placing the valve upstream
is slow turn off. The gas must bleed through the laminar flow
element after the gas is turned off. The bleed downtime is a
function of gas properties, the laminar flow element volume
upstream of the LFE, and pressure in the upstream volume. For
multi-sensor diagnostics, the manufacturer takes advantage
of the bleed-down and characterizes the pressure decay every
time the MFC is given a command to shut off. Any deviation
from baseline signifies a change in either the LFE flow path
or pressure sensors, and would trigger the user to perform a
maintenance check.
Active self-diagnostics
Unlike idle self-diagnostics, where MFC
characterization is performed when the MFC is
not running a process, the latest development in
multi-sensor self-diagnostics enables true in situ
flow verification. This means flow anomalies can
be captured in real-time during a process and
assessed before several wafers are affected.
FIGURE 5 shows the cross-section of a multi-
sensor self-diagnostic MFC mounted on a
traditional surface mount gas stick. In this
example, the MFC contains a pilot valve that
enables the MFC to control the state of the
upstream isolation valve. Other implementations
integrate the isolation valve into the body of the MFC.
The MFC closes the upstream
isolation valve when it is ready to
take a secondary flow measurement.
This creates a fixed volume between
the isolation valve and the MFC
control valve. While pressure decays
in the volume, the MFC control
system continues to maintain
flow while recording pressure,
temperature and time. A secondary
flow measurement is computed
based on the pressure decay (ROD)
and compared to baseline data
recorded during the installation of
the MFC on the tool. Once this measurement is complete, the
MFC re-opens the isolation valve. PTI technology is used to
compensate for the initial pressure spike, ensuring continued
stable flow. The same measurement technique can be used to
monitor zero drift and valve leak when the MFC is given a zero
set point.
Case study on etch process tool at
leading IDM
Two multi-sensor MFCs capable of active self-diagnostics were
installed on an etch chamber at a major integrated device
manufacturer. The MFCs were configured to store accuracy, zero
drift and valve leak self-diagnostic data in flash memory located
within the MFC. Performance transparency tests were run with
self-diagnostics activated to ensure the technology did not
change the process.
FIGURE 5. Thermal MFC active self-diagnostics.
FIGURE 4. Pressure-based MFC idle self-diagnostics
WP-A New Class of MFCs with Embedded Flow Diagnostics
June 2016
4. The process engineers continued to perform regular off-line
flow verification tests at a set point of 30 percent. No accuracy
issues were detected by the traditional maintenance tests
and no adjustments such as re-zeroing or re-calibration were
performed. Data was collected for 24 months.
Active multi-sensor diagnostics vs. off-line chamber ROR:
Self-diagnostic data was collected during the regular off-line
flow verification tests. FIGURE 6 shows that repeatability of
self-diagnostics was 8X better than the time-consuming off-line
flow verification tests.
Active flow accuracy: The etch process utilized MFC set points
of 4 percent, 12 percent, 24 percent and 40 percent (FIGURE 7).
In situ active self-diagnostic data was automatically collected at
each set point every three seconds during wafer processing. The
MFC flow accuracy was very repeatable over the two-year test
period at set points of 24 percent and 40 percent.
However, flow accuracy at 4 percent shows an increase in flow of
1 percent over the two-year evaluation period. Note that off-line
flow verification tests were only performed at a set point of 30
percent where the MFC is stable. Traditional off-line chamber
ROR flow tests proved not only to be costly, but also ineffective
in detecting flow changes in this case.
In situ zero drift trending: Increasing flow errors at low set points
usually indicate a change in the zero of the flow meter. The
output of a flow meter should be zero at no flow. However, all
measurement instruments will eventually drift resulting in some
level of zero offset. A small zero offset in the flow meter is a
negligible part of the flow signal at a high flow rate.
FIGURE 7. In situ flow accuracy results.
FIGURE 6. Chamber ROR flow verification vs. multi-sensor
self-diagnostics.
WP-A New Class of MFCs with Embedded Flow Diagnostics
June 2016
5. However, small zero offsets can become significant when the
MFC is operated at low set point such as 4 percent shown in
this tool data. Consequently, the self-diagnostic zero reading
was analyzed to see if the accuracy error at a 4 percent set point
correlated with zero drift.
The MFC zero drift rate was < 0.027 percent full scale (FS) per
year. This is exceptionally stable and 20X less than the spec limit
(FIGURE 8). No maintenance test performed today on-tool
would identify this low level of zero drift. This data highlights
recent improvements in the stability of thermal MFCs. However,
expanding the zero drift axis does reveal a slight trend in zero of
0.045 percent FS. This offset is exactly equal to the 1.1 percent
of reading flow error identified during process runs at the 4
percent set point
Valve leak: Valve leak is linked to first wafer effects and can
indicate contamination in the gas delivery line. Excessive valve
leak can cause loss of control at low set points. Self-diagnostic
valve leak was trended during this study.
The MFC valve leak was extremely low and stable throughout
the study (FIGURE 9). Process engineers typically get concerned
when valve leak reaches 0.5 percent FS to 1.0 percent FS. The
data reveals excellent resolution of the valve measurement
and demonstrates how easy it would be to detect changes in
valve leak well before it could affect process yield.
TABLE 1 compares data and resolution available in situ from
a traditional MFC; a tool in idle mode; a tool off-line; and the
active multi-sensor self-diagnostic data captured in this study.
The process knowledge gained from this technology enables
the process engineer to be proactive instead of reactive. In
addition, an intelligent FDC system could use this data to
identify more subtle MFC issues such as excessive sensitivity to
changes in pressure or temperature, and even leaks in the gas
stick isolation valves
Conclusions
This data highlights how current best known methods for MFC
on-tool monitoring and off-line maintenance are unable to
capture changes in process and ensure repeatability.
TABLE 1.
WP-A New Class of MFCs with Embedded Flow Diagnostics
June 2016
FIGURE 8. In situ zero trending results
(20x magnification)
FIGURE 9. In situ valve leak results.