Guided wave radar
Guided wave radar
Guided wave radar
Guided wave radar

Absolute Energy LLC has installed Emerson’s Rosemount guided wave radar (GWR) and chamber technology to monitor the water level in a condensate receiver for a sieve dehydration process at its ethanol production facility near Lyle, Minnesota, USA. Replacing the plant’s existing level transmitters, the new equipment has helped avoid shutdowns that can cost as much as 13,500 Euros an hour in lost production and potential equipment damage costing over 135,000 Euros. “Our condensate receiver levels went from being a constant headache to being hardly noticeable because the GWR is so reliable,” said Travis Rosenberg, Maintenance Manager, Absolute Energy. “The increased reliability has helped us to lower the risk of equipment damage, increase plant availability, decrease energy and utilities costs and reduce maintenance costs.” The 435 million litre per year plant identified a way of improving operations by increasing the reliability and availability of the condensate receiver tank on the steam heat exchanger. The availability of the condensate receiver is critical to continuous operation of the heat exchanger and molecular sieve dehydration process. If water levels get too high in the receiver, temperatures in the heat exchanger drop, which can cause wet ethanol to enter the molecular sieve beds. This forces the process to be shut down and the ethanol-water mixture to be reprocessed. Previously, the level measurement was performed by DP transmitters mounted on wet legs. Excursions from high vacuum to low pressure in the condenser make it challenging for DP technology to monitor the levels in the tank reliably. The pressure changes can cause the fill heights in the wet legs to vary widely, making it difficult to get a reading during start-up and providing errors in accuracy of as much as 20%. Also DP technology is affected by density changes of the measured fluid, which impacts the accuracy as well. The unreliable level measurements affected operations. When the condensate levels got too high, the upset led to a molecular sieve dehydration process shutdown – which can cost as much as 13,500 Euros in lost production per hour. If temperatures drop in the heat exchanger and the upset occurs before the wet process stream is sent into the sieve beds, the heat exchanger has to be shut down and restarted. It then takes 20-30 minutes to get the process running at full speed, resulting in decreased throughput and increased energy costs. This type of upset occurred every other week. If the upset occurs and the sieve beds get wet, the process shutdown lasts between 36 and 48 hours because the beds must be shut down, regenerated, and restarted. While this type of upset is not common, wet sieve bed occurrences eventually lead to extensive equipment damage that combined cost over 135,000 Euros. To address these challenges, Absolute Energy replaced the DP measurement with Emerson’s Rosemount 5301 Guided Wave Radar (GWR) and a Rosemount 9901 Chamber. This Rosemount 5301 GWR provides a highly accurate and reliable direct level measurement. The major advantage of GWR technology is that it is independent of density changes and it manages changing pressure conditions without compromising reliability. A Rosemount 9901 self-contained chamber was installed for externally mounting the Rosemount GWR to the vessel. This arrangement enables the instrument to be isolated for routine maintenance while keeping the plant operational. Installation was very easy, as the chamber was simply mounted on the existing process connections. The improved control of levels in the condensate receiver means this measurement point is no longer a maintenance headache. As a result, Absolute Energy has increased plant availability, decreased energy and utilities costs, reduced maintenance costs, and lowered the risk of equipment damage.

Posted on June 21, 2011 - (15520 views)
Emerson Automation Solutions
Blegistrasse 21
6341 Baar - Switzerland
View full company profile
More products from this supplier
Mobile Platform DeltaV™
It’s Time for Project Certainty
Batch Analytics Deployment
Burner management system
USB Fieldbus Interface
Direct insertion meter
Oil and gas platform
Oil and gas platform
Density meter
Emergency shutoff valve
Pump health monitoring
Smart Combustion technologies
Oil and gas platform
Automation technologies
Guided wave radar
Coriolis flowmeters
Smart Wireless
Wireless acoustic transmitter
Coriolis meters
I/O on demand technology
Related articles
Sil Certified Vortex Flow Meters
TorqSense Torque Transducers
Immediate Quantification of Gas Leaks
Oscilloscope Series RTC1000, RTM3000 and RTA4000
Process Monitoring and Control System ComoNeo 2.1.0
FieldMate Device Management Software
Leak Detection Technology Prevents Power Outages
Digital Probe EE871
Unique Mixproof High Alloy and UltraPure Valve
Calibration Instrument LS3300
Keller OEM Pressure Transmitters
Moisture in Oil Transmitters
Cabinet and Panel Solutions
Electrical Explosion Protection Equipment
Process Pressure Transmitter dTRANS p20
Hannay Reels is the Reel Leader
80 GHz Radar Level Sensor VEGAPULS 64
Hannay Reels: The Reel Leader
On-line Turbidity Measurement: PTV 1000/2000 Lovibond® Water Testing
Siemens Process Instrumentation: Measuring Everything that Matters
Leak Detection Technology Prevents Power Outages
Calibration Instrument LS3300
Cabinet and Panel Solutions
On-line Turbidity Measurement: PTV 1000/2000 Lovibond® Water Testing
BLE-Beacon Technology
On-line Turbidity Measurement - Lovibond Water Testing PTV 1000/2000
The Italian Manufacturer of Rupture Discs
Piezoresistive OEM Pressure Transmitters
The Italian Manufacturer of Rupture Discs
Onshore and Offshore Safe Networking
Combustion Gas and Emissions Analyzer
Air / Gas Thermal Mass Flow Meter
Flameless Venting
Ultrasonic Flow Meter ES-FLOW
Radar Level Sensor for Liquids with 80 GHz
European Plant with Boosted Process Equipment Manufacturing Capability
Aspirating Smoke Detector
Optical Gas Imaging Camera GF Series
Discover Machine Builders’ 1st Choice for Remote Maintenance: video
Electromagnetic Flowmeter Proline Promag D 400