OEM Solutions Handbook

and Desk Reference

What every OEM needs to know about
selecting an instrumentation supplier
 Endress+Hauser
OEM Solutions Handbook and
Desk Reference
2004 Edition

Be sure to visit our web site, www.us.endress.com/OEM

Endress+Hauser, Inc. Phone: 888-ENDRESS

2350 Endress Place (in Canada 800-668-3199)
Greenwood, IN 46143
Phone: 317-535-7138

Service: 800-642-8737 for support of your installed base

© 2004 Endress+Hauser

Endress+Hauser reserves the right to change or modify our product appearance and specifications at any time
without notice. Though the information provided herein is believed to be accurate, be advised that the informa-
tion contained herein is NOT a guarantee for satisfactory results.

2
Table of Contents
Introduction to Endress+Hauser ......................4
History...........................................................4
Milestones .....................................................5
Driven by the knowledge that powers
a global company ...........................................7
OEM Success Stories ......................................7
U.S. Representatives .......................................8
Frequently Asked Questions (to ask the
instrument supplier you select) ...................... 10
Innovations ....................................................... 13
Endress+Hauser Honors Inventive
Genius ......................................................... 13
Awards ........................................................ 14
Exposure via Magazine Articles and
Reports ........................................................ 15
Introduction to Basic Measurement
Technologies ..................................................... 17
Level: RF Capacitance Measurement ............ 17
Level: Conductive vs. Nonconductive........... 17
Level: Vessel Construction ........................... 17
Level: Vibration Level Switch ....................... 18
Level: Ultrasonic Level Measurement........... 18
Level: Radar Level Measurement.................. 18
Flow: Electromagnetic Flow Measurement .. 19
Flow: Coriolis Mass Flow Measurement ....... 19
Flow: Vortex Shedding Flow Measurement ..20
Flow: Ultrasonic Flow Measurement ............20
Pressure: Gauge/Absolute Pressure
Measurement............................................... 21
Pressure: Differential Pressure
Measurement...............................................22
Pressure: Hydrostatic Pressure
Measurement...............................................22
Analysis: pH ................................................23
Analysis: ORP ..............................................23
Analysis: Conductivity .................................23
Analysis: Dissolved Oxygen .........................23
Analysis: Chlorine .......................................24
Analysis: Turbidity .......................................24
Temperature ................................................24
Endress+Hauser Product Offering .................26
Services .......................................................26
Pressure Products ........................................ 27
Level Products .............................................28
Analysis Products ........................................ 29
Flow Products ..............................................30
Temperature Products .................................. 32
Recorder & Process Display Products ............33
Digital Communications ..............................38
Successful Application Solutions .................... 39
Equipment Manufacturer — Filling
Machines ..................................................... 39
Food & Beverage Industry — Packaging
Machinery ................................................... 41
Beverage Industry — Filling Machines ........ 42
Equipment Manufacturer — Net Weight
Filling System ..............................................44
Food Industry — Dairy ................................45
Food & Beverage Industry ............................ 47
Pharmaceutical Industry — Purified Water .. 50
Pharmaceutical Industry — Purified Water .. 52
Pharmaceutical Industry — Purified Water ..54
Pharmaceutical Industry — Fermentation.... 56
Pharmaceutical Industry — Fermentation.... 58
Pharmaceutical Industry — Purified Water ..60
Pharmaceutical Industry — Media
Preparation .................................................. 62
Water Industry — Desalination Systems ......64
Wastewater Industry — Fresh & Clean
Water ........................................................... 65
Chemical Industry — Seal Pots ....................66
Fieldgate ......................................................68
Biotechnology Industry — Measuring Cart .. 69
Endress+Hauser Safety .................................70
Endress+Hauser Earns Laboratory
Approval ...................................................... 70
In Safe Hands............................................... 70
Advantages of an Intrinsically Safe Barrier ... 72
Safety instrumented systems ........................ 73
Measured Data Recording Compliant to
21 CFR Part 11: Blessing or Curse ................ 78
Explosion Protection in Process
Automation .................................................. 82
Endress+Hauser e-Direct ................................ 87
Glossary of Instrumentation Terms ............... 91
Compatibility Tables & Conversion
Charts ...............................................................113
Magnetic Flowmeters .................................118
English to Metric System Conversion ......... 125
Equivalents ................................................ 127
Services ........................................................... 129
3
Introduction to Endress+Hauser
Endress+Hauser is a global supplier of process automation solutions. The company develops, manufactures and
sells sensors and systems for production and logistics in the process industry. These products acquire, trans-
mit and use process information. The products are excellent in both performance and price; the services are
ground-breaking. Both aid customers’ competitiveness with a maximum of quality, safety and efficiency.

To complement its own strengths appropriately, Endress+Hauser collaborates with universities and research
institutes, as well as with other business partners and competitors. In parallel, the company continues to
expand its industry know-how, and ensures the competence of Sales and Service. A tight network of production
and sales companies, together with representatives, gives Endress+Hauser a very strong presence across global
markets.

The company owes its good reputation to employees’ competence, creativity and commitment. Endress+Hauser
behaves responsibly towards the community and environment, and is commerically successful. The financially
strong and independent family company stands for continuity, the broadest range in its industry, and active
relationships. Endress+Hauser seeks to be its customers’ preferred partner throughout the world.

History
Endress+Hauser was founded by Georg H. Endress and Ludwig Hauser in 1953. It all began as a vision - the
use of electronics for the remote measurement of level in containers, tanks and silos, on a reliable and accurate
basis.

Endress+Hauser products are manufactured at modern day Product Centers, using the newest manufactur-
ing techniques available, and continuing to update equipment as technology changes. Each Product Center is
responsible for a particular measuring technology; level products are designed and built by one Product Center,
while flow measuring products are designed and built by another. This unique philosophy allows research and
development to focus on a particular measurement technology. At the same time, the various technologies and
best practices are shared among the other Product Centers, giving rise to new ideas, designs, and products that
are unsurpassed by any other measurement manufacturer.

Level measurement at Endress+Hauser has grown from single-point capacitance switches to continuous
level measurement. Enhancing the various needs of industry, frequency shift tuning fork level switches from
Endress+Hauser have become the standard for basic level switches. For agressive materials, ultrasonic and radar
measurement systems have been developed to meet all the level measurement requirements in industries where
non-contact measuring is needed.

As our growth has continued in the field of level measurement, other fields have been added to achieve world-
wide leadership. In 1977, Endress+Hauser met the need for more accurate and dependable liquid flow measur-
ing by introducing a line of electromagnetic flowmeters. As with our level instrumentation, the challenge for
more accurate flowmeters and various types of in-line connections was met by Endress+Hauser. From the basic
magnetic flowmeter to the microprocessor controlled systems of today, Endress+Hauser meets and exceeds the
industry standards. As a company grows, so must its product base. Conductive fluids are just one medium of
liquids flow. What about steam, gas, and non-conductive fluids? Once again, Endress+Hauser met the chal-
lenge by introducing a specialized vortex flowmeter. For industries that require mass flow and volumetric flow
measurement, Endress+Hauser offers the Coriolis mass flow measuring system. This is the ultimate in mass
flow technology, using straight through flow tubes, and a secondary containment vessel to ensure process
safety.

Our commitment to further provide industry with a full line of measurement systems led our research and
development engineers into the pressure field. Using our capacitance knowledge and ceramics, Endress+Hauser
overcame the limitations inherent to conventional pressure sensors. We now produce ceramic, capacitive pres-
sure measuring cells coupled with hybrid integrated circuits, capable of withstanding over-pressure loads up

4
to 800 times rated pressure. Our sensors provide long-term stability in aggressive environments with various
process connections to fit your industrial applications. Endress+Hauser offers systems to measure processes
from vacuum to 6000 psig, differential pressure systems, and hydrostatic pressure systems.

Industrial requirements continue to rise, and so does the need for accurate recording instruments.
Endress+Hauser not only provides traditional recorders for which there is still a need, but also recording devices
that plot continuous colored traces, print data, record process events, and notify alarm status. Our commitment
to perfection allows all that information to be provided simultaneously in stand-alone monitoring units or
integrated into your process control system.

Endress+Hauser is committed to the industries we serve. We develop, manufacture and sell sensors, transmit-
ters and systems, which extract information from manufacturing procedures in the processing industry and
prepare it for use by process control systems. The physical variables include level, pressure, flow, analytical and
temperature, as well as industrial components. Our goal is to continue our commitment to new products and
services for our valued customers.

Milestones
1953 L. Hauser KG, founded by the Swiss engineer Georg H. Endress (29) and the German banker Ludwig
Hauser (59) starts activities in Lörrach. The company markets level meters made by the British
manufacturer, Fielden Electronic.

1956 The first two measurement devices developed by G. H. Endress join the product range. They are
produced in a former joiner’s workshop in Lörrach-Stetten and in surrounding buildings.

1959 The fledgling company is now renamed ”Endress+Hauser GmbH.”

1960 The first branch office abroad opens in Amersfoort, the Netherlands, shortly followed by the second in
Switzerland.

1961 The fast growing company, now with 120 employees, relocates to a new building in the nearby rural
community of Maulburg.

1962 Subsidiaries are founded in Saint-Louis France and Brussels.

1968 Mestra AG is founded in Basel as holding company for the group, forerunner of the present day
Endress+Hauser Holding AG in Reinach.

1970 Endress+Hauser opens up markets outside Europe: subsidiary near Boston, MA, share in Sakura
Instrument Co. Ltd., Tokyo.

1971 Ludwig Hauser, now 76, retires from his post of CEO. He dies four years later. The Hauser family
withdraws, leaving the Endress family as sole shareholder.

1974 Endress+Hauser sales center in the USA is relocated from Beverly, MA to Greenwood, IN.

1976 Endress+Hauser expands into new work areas by taking over Wetzer (measurement recording) in
Pfronten.
.
1977 Endress+Hauser takes over the majority shareholding in Conducta (analytical measurement) in
Gerlingen near Stuttgart. Flowtec AG (flow measurement) is founded in Reinach.

1980 A research and development center is built in Maulburg for seven million Deutschmarks.
Microelectronics arrive: the world’s first level switch with total self-monitoring is launched.

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1981 Endress+Hauser Flowtec AG launches its first electromagnetic flowmeter on the market with great
success. Endress+Hauser Maulburg inaugurates a laboratory for thin-film technology; it will become
the basis for the new ”Pressure measurement” work area.

1983 The ”Liquiphant”, a revolutionary level switch working on the tuning fork principle, is born. It is
joined by ultrasonic transmitters and radiometric processes for level measurement.

1986 The m-point, Endress+Hauser Flowtec AG introduces the first straight-pipe mass flowmeter based on
the Coriolis principle and receives an innovation award for its work.

1987 U.S. Flow Production facility opens with a precision Flow Calibration Lab.

1989 The ”Trinational Apprentice Training Program” is started: during their apprenticeship, apprentices
switch beween German, French and Swiss Endress+Hauser companies. An Endress+Hauser
subsidiary starts in Hong Kong.

1990 In Germany, sales and service are restructured in separate companies. Endress+Hauser companies are
founded in Malaysia, Canada and Spain.

1991 Endress+Hauser Flowtec AG starts a production center for flowmeters in Cernay. Endress+Hauser
Conducta starts another production center for pH electrodes in Waldheim, in eastern Germany.

1992 First certification to ISO 9000. The first instruments with Fieldbus communication are launched. The
standard which Endress+Hauser helped to develop allows the bidirectional digital transmission of
data between sensor and control center.

1993 The Sales Center for Germany and the Information Center for the entire group start operation in Weil
am Rhein.

1995 Generation change at the head of the company: Klaus Endress, second son of the company’s founder,
takes over from his father Dr. h.c. Georg H. Endress as CEO (Chief Executive Officer) of the group of
companies.

1996 The production of level measurement devices starts in Shanghai (China). Endress+Hauser subsidiaries
start up in Poland and India.

1997 Endress+Hauser USA expands production operations again and opens new Sales Center facility.

1998 Profibus PA helps fieldbus technology to break through in process automation. A company Sales
Center starts up in Korea.

1999 Endress+Hauser forms the Systems & Gauging Division and consolidates the activities of Whessoe-
Varec, Sakura Endress and Coggins Systems.

2000 Endress+Hauser increases its presence on other growth markets. Beijing Instrument Co. (China)
becomes an Endress+Hauser subsidiary; a new production center for flowmeters opens in Aurangabad
(India). Analytical measurement is expanded by strategic acquisitions of Innovative Sensors Inc. and
Wedgewood Technologies, both in the USA. New Sales Centers open in Mexico and Chile.

2001 Hungary and Ireland join the group as new Sales Centers in Europe; through the startup of
Endress+Hauser in Australia in Sydney, the company is now present on all five continents.

2002 Endress+Hauser USA inaugurates five new Regional Centers across the country to provide service and
support closer to the customer.

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Driven by the knowledge that powers a global company.

Endress+Hauser is a global supplier of process

automation solutions. The power of this global
company is intensified by its local support to you.
This support starts with excellent manufacturing
facilities located within the US. ISO 9001 certified
manufacturing facilities and ISO/IEC 17025 accredited
calibration systems assure Endress+Hauser delivers
highly reliable measuring instruments to customers
throughout North and South America.

A network of skilled sales and service personnel are

located worldwide, ready to provide the customer
support required. Local sales and service locations
assure there is someone available, in your time zone, US calibration capability is accredited according to
to support you with knowledgeable technicians, spare ISO/IEC 17025, NIST traceable
parts inventory and calibration facilities.

OEM Success Stories

Major international equipment builders as well as small machine builders in a variety of industries rely on
Endress+Hauser as their partner to provide the instrumentation they need.

Endress+Hauser is committed to long-term relationships with many OEMs and can offer unique, custom-fitted
solutions for practically any measurement requirement, and the long-term local support that is required.

Proven Success Stories (partial list):

Food/Beverage & Health/Personal Care Pharmaceutical

• APV • Millipore
• Tuchenhagen/GEA • GEA
• Cherry Burrrell • Novasep
• MRN/Elgin • Cotter
• Alfa Laval • Mengibar
• TetraPak • Moog
• Pnuematic Scales
• Ronchi Water
• Klockner HKS • US Filter/NIRO
• Crown-Simplimatic • BioDigester Technologies
• Ionics
Chemical • Osmonics
• NALCO Chemical
• NOVUS International
• Durr/Henry Filters
• Halliburton
• Whessoe Vaarec

7
U.S. Representatives

To contact your Regional Sales Center, call 888-ENDRESS (363-7377) or choose a local representative listed
below.
Alabama Delaware Iowa Nebraska
TriNova, Inc. Endress+Hauser Fluid Technology Corporation Fluid Technology Corporation
Mobile, AL Chalfont, PA Des Moines, IA Des Moines, IA
251-378-7837 215-712-9050 515-263-9210 515-263-9210

TriNova, Inc. Philip R. Walker & Associates Kansas Nevada

Bessemer, AL Cockeysville, MD Compass Controls and Enterprise Inc.
205-426-0494 410-666-2142 Instrumentation Las Vegas, NV
Shawnee, KS 702-259-9580
Alaska FOR MUNICIPAL INDUSTRY 913-441-9779
North Coast Electric Co. LRM Inc. IPT Sales Company
Anchorage, AK Souderton, PA Kentucky San Francisco, CA
907-563-5229 215-721-4840 George E. Booth Co., Inc. 415-824-3679
Indianapolis, IN
Arizona Florida 317-247-0100 Weidner & Associates
Industrial Automation Instruments South Corp. Midvale, UT
Services Lakeland, FL Louisiana 801-565-9595
Chandler, AZ 863-499-0146 Endress+Hauser
480-413-0899 Louisiana New Hampshire
Georgia 985-652-3265 O‘Connor & Senecal, Inc.
Arkansas Instruments South Corp. Sutton, MA
TriNova, Inc. Savannah, GA Maine 508-865-5600
Mobile, AL 912-898-0388 O‘Connor & Senecal, Inc.
251-378-7837 Sutton, MA New Jersey
Hawaii 508-865-5600 Endress+Hauser
Endress+Hauser Harrington Plastics Chalfont, PA
Louisiana Pearl City, HI Maryland 215-712-9050
985-652-3265 808-487-5524 Philip R. Walker & Associates
Cockeysville, MD FOR MUNICIPAL INDUSTRY
M & D Controls Idaho 410-666-2142 LRM Inc.
Tulsa, OK Tourangeau Nor Wes Souderton, PA
918-664-7511 Tualatin, OR Massachusetts 215-721-4840
503-691-6100 O‘Connor & Senecal, Inc.
California Sutton, MA FOR MUNICIPAL INDUSTRY
IPT Sales Company Weidner & Associates 508-865-5600 ZMW Associates
San Francisco, CA Midvale, UT Staten Island, NY
415-824-3679 801-565-9595 Michigan 718-370-3833
MAC Systems
Process Instruments Illinois Waukesha, WI New Mexico
Bakersfield, CA Antel Corporation 262-544-6100 Industrial Automation
661-327-7000 Willowbrook, IL Services
630-887-8910 Sterling IPC Chandler, AZ
RPS Industries Div. of Endress+Hauser 480-413-0899
Div. of Endress+Hauser George E. Booth Co., Inc. 586-752-0700
Brea, CA Indianapolis, IN Pan-Tech Controls
714-529-1925 317-247-0100 Minnesota Arlington, TX
Engineered Sales Company 817-640-3232
FOR MUNICIPAL INDUSTRY Fluid Technology Corporation Bloomington, MN
CP Crowley Des Moines, IA 952-888-1131 New York
San Dimas, CA 515-263-9210 Control Equipment
909-592-1500 Mississippi Corporation
R.L. Weisheimer & Assoc. TriNova, Inc. Cazenovia, NY
Colorado Columbia, IL Mobile, AL 315-655-9700
Beabout Company 618-281-4148 251-378-7837
Littleton, CO Endress+Hauser
303-795-1000 Indiana Missouri Chalfont, PA
Antel Corporation Compass Controls and 215-712-9050
Connecticut Willowbrook, IL Instrumentation
O‘Connor & Senecal, Inc. 630-887-8910 Shawnee, KS FOR MUNICIPAL INDUSTRY
Sutton, MA 913-441-9779 ZMW Associates
508-865-5600 George E. Booth Co., Inc. Staten Island, NY
Indianapolis, IN R.L. Weisheimer & Assoc. 718-370-3833
317-247-0100 Columbia, IL
618-281-4148

8
North Carolina Tennessee Washington D.C.
A.D. Instruments Instruments South Corp. Philip R. Walker & Associates
Div. of Endress+Hauser Greeneville, TN Cockeysville, MD
Charlotte, NC 423-639-3800 410-666-2142
704-969-7974
TriNova, Inc. West Virginia
North Dakota Mobile, AL Cavcon, Inc.
Engineered Sales Company 251-378-7837 Charleston, WV
Bloomington, MN 304-342-0385
952-888-1131 TriNova, Inc.
Memphis, TN Wisconsin
Ohio 901-684-7099 Engineered Sales Company
George E. Booth Co., Inc. Bloomington, MN
Indianapolis, IN Texas 952-888-1131
317-247-0100 Endress+Hauser
Houston, TX MAC Systems
McStay Engineered Products 713-300-6268 Waukesha, WI
Cleveland, OH 262-544-6100
440-439-7208 M & D Controls
Tulsa, OK Wyoming
Oklahoma 918-664-7511 Beabout Company
M & D Controls Littleton, CO
Tulsa, OK Measurement Resources 303-795-1000
918-664-7511 Corpus Christi, TX
361-882-3444 Weidner & Associates
Oregon Midvale, UT
Tourangeau Nor Wes Pan-Tech Controls 801-565-9595
Tualatin, OR Arlington, TX
503-691-6100 817-640-3232 Puerto Rico
Parker Sales & Engineering
Pennsylvania Endress+Hauser Santurce, PR
LH Boleky Louisiana 787-722-3061
Pittsburgh, PA 985-652-3265
412-931-5053
Utah
Endress+Hauser Weidner & Associates
Chalfont, PA Midvale, UT
215-712-9050 801-565-9595

McStay Engineered Products Vermont

Cleveland, OH O‘Connor & Senecal, Inc.
440-439-7208 Sutton, MA
508-865-5600
FOR MUNICIPAL INDUSTRY
LRM Inc. Virginia
Souderton, PA Century Control Systems,
215-721-4840 Inc.
Daleville, VA
Rhode Island 540-992-5100
O‘Connor & Senecal, Inc.
Sutton, MA Philip R. Walker & Associates
508-865-5600 Cockeysville, MD
410-666-2142
South Carolina
A.D. Instruments Washington
Div. of Endress+Hauser Tourangeau Nor Wes
Charlotte, NC Tualatin, OR
704-969-7974 503-691-6100

South Dakota Tourangeau Nor Wes

Engineered Sales Company Snohomish, WA
Bloomington, MN 425-338-4477
952-888-1131

9
F.A.Q.s: Questions to ask the
instrumentation supplier you select

Feel free to ask any supplier you are considering these

questions, and then compare their responses to the ones
below from Endress+Hauser.
Are your products and supporting documents multilingual so they can be utilized in any area of the
world where they may end up? Yes, documents like owner’s manuals are written in multiple languages,
and the software (firmware) when used on Endress+Hauser instrumentation is normally written in a minimum
of four languages, sometimes more, so the proper display text can be selected. This is the benefit of working
with a truly “Global” supplier.

My machines get shipped around the world. Do your designs meet the regulations and standards
outside of this country? Yes, Endress+Hauser instruments are designed for worldwide use, meeting safety,
quality and industry standards in numerous countries. These standards include approvals for Hazardous Locati-
ons as well as standards for the Food and Pharmaceutical markets.

Do you have service personnel located around the world to assist with the start-up or any opera-
tional issues down the road? Yes, virtually every industrialized nation has offices with factory-trained,
Endress+Hauser service technicians, and in other nations, associated organizations exist to provide assistance
in those remote locations. The worldwide Endress+Hauser service organization covers over 90 countries in all
and many offer support 24 hours a day.

Do you stock spare parts in every region around the world? Yes, the sales & service network for
Endress+Hauser covers countries on the six main continents with a local supply of spares parts and accessories
when needed, therefore any special requirements identified can easily be maintained.

Do you offer a broad product basket of new devices, so there is no need to force fit one certain
technology? Yes, since Endress+Hauser offers the broadest range of measurement solutions from any single
supplier, you are assured that limited approaches to a problem are not all that would be considered for your
needs. We can help you select the right solution, and avoid forcing just one or two options into applications
where it would not be ideal technology in terms of performance or economy.

Do you offer online selection (Engineering) software available free of charge, 24 hrs. a day, to assist
our design people and simplify the proper selection of the right instrument? Yes, Endress+Hauser has
the “Applicator” selection tool online at our website for anyone needing help in determining what instrument
will work best in any given application. Visit http://www.us.endress.com/applicator.

Does your company have a track record of long-term stability and offer the confidence you’ll be
around to support me in the future? Endress+Hauser has been around for over 50 years (since 1953) as
the same company, with the same ownership, stable management, under the same name. As opposed to a lot
of companies that have been acquired, or absorbed into large conglomerates, and relocated or closed, that have
weak linkage back to the original company you may have purchased from. Endress+Hauser has shown consis-
tent growth as a result of sound business management since its formation as a company.

10
Does your company’s investment in R&D compare with that of the typical company in your
industry? For years, Endress+Hauser has invested around 10% of its revenues back into product development,
which is nearly double the industry norm, to offer its customers the best possible instrumentation designs. The
results are a continual stream of new, leading-edge products with features that offer unique and real benefits to
OEMs and end users by being able to take advantage of the newest technology available.

Has your company come up with any “Industry Firsts” in instrumentation design? Endress+Hauser
has recorded ”firsts” in the market year after year, since its inception in 1953. This is what has set them apart
from many other manufacturers. On average, Endress+Hauser introduces about 10 new major products each
year, which is unmatched by any other instrumentation company.

What do you have to demonstrate this innovation? Numerous Awards & Patents have been issued to
Endress+Hauser, including over 150 patent applications in just the 2003 timeframe. See following section.

Does your company support an open digital protocol philosophy, so proprietary control platform
or software is never dictated? Yes, Endress+Hauser has always maintained a product position of allowing
our instruments to work with any control platform. Endress+Hauser is an innovator in the areas of digital
communications, being the first with many solutions for HART®, FOUNDATION FieldbusTM, Profibus® and
other protocols, and actively participates in and promotes open standards, such as the new multi-vendor FDT
solution. For more information, visit http://www.fdt-jig.org. Download Documents SD 013S, SI 006S, SI 005S.

Do you offer unrivaled production facilities and calibration capabilities? Endress+Hauser operates
modern, state-of-the-art manufacturing facilities meeting ISO9000 quality standards, complete with
calibration capabilities in numerous countries that have been rated as virtually equaling the National Standards
laboratories. The calibration systems are all certified to the newest ISO17025 standard, which is the guideline
now being followed for traceability by NIST, SCS and other agencies.

Do you offer products developed specifically for OEM applications in partnership with the
customer? Yes, Endress+Hauser has done this on many occasions, an excellent example of this are the
Dosimag and Dosimass flowmeters, which are Electromagnetic and Coriolis technologies designed as
complimentary products specifically to give liquid filling machine builders a choice of modern solutions for
volumetric or mass filling applications.

Do you have a proven track record with major OEMs around the world and the ability to work
locally with even the smallest customers? Yes, our OEM customer list is extensive, and includes small
shops with single locations, as well as some of the largest, most recognized names in the machine building
business in industries such as Chemical, Food & Beverage, Pharmaceutical, Water Treatment, Health & Personal
Care, etc.

How do you rank among the leading instrumentation suppliers? Endress+Hauser is the largest
private instrument and measurement solution supplier in the world, focused solely on instrumentation. With
this concentrated focus we are able to provide the best in class in all measurement technologies, which is
demonstrated every day in tough applications.

Does your company operate with a clear Vision and Mission? All 6000+ Endress+Hauser employees
around the world follow the same Credo, with the number 1 priority being the Customer. The Endress+Hauser
Vision states “Customers identify Endress+Hauser as the international solution supplier with a wide range
of process measurement instrumentation and a strong presence worldwide. We develop our employees, we
foster a responsible attitude towards the community and our environment, while ensuring economic success.
Endress+Hauser strives to be: ”Simply the BEST.”

Do you offer a convenient online method to quickly determine the spare parts requirements
(24 hrs. a day) for your specific model? Endress+Hauser has developed the W@MTM concept (Web-
enabled Asset Management), which offers a unique solution for determining the correct spare parts for any
Endress+Hauser instrument simply by accessing our website and typing in your model number. No more
searching through manuals, or trying to find phone numbers for the right place to call in order to get needed

11
information. It will be as close as your computer, even if you weren’t the company which initially purchased
the device – so end users wherever they may be have quick access to this data. Download Document SI 001Z.

Do you offer an online solution to rapidly determine an instrument’s origin (by serial number), date
of production, configuration, related documents (eg: manuals) approvals certificates, calibration
history, etc.? Yes, as part of W@MTM any user can quickly find the critical information related to any specific
device by accessing the Endress+Hauser production database information provided online. Imagine the time
and cost savings by having a single “go-to” location to always find needed documentation related to any
measurement device, even life-cycle information like repair events, upgrade records, calibration history, etc. at
any time, whenever necessary just by using your Internet browser.

Can you offer an Asset Management solution outside of a DCS environment to benefit OEMs & End
Users? Yes, with the FieldCareTM platform, Endress+Hauser can tailor various levels of Asset Management
to specific end users’ needs regardless of the type of control platform selected, and even where installations
are absent of a uniform control technology. So Endress+Hauser can provide benefits whether or not a single
control solution exists. And the W@MTM concept offers access to much of this capability 24 hours a day online.
Download Document SI 013S.

Are you able to offer Remote Maintenance capabilities? Yes, with the unique FieldGate™ technology,
Endress+Hauser has a way to assist users remotely to diagnose problems in the field, and perform remote
programming or software upgrades so costly service visits can be avoided. Download PK 001V.

Are your company’s business operations modern enough to allow for future e-Business transaction
capabilities (per request) or is product available for purchase through an online shop? Yes, based on
the mySAP CRM e-Shop platform, direct transactions are possible once buyer/seller ERP system compatibility
is analyzed and found appropriate, steps can be taken to interconnect the two systems. Plus an online shop
already exists today where many OEM type products can simply be ordered with a Credit Card or Purchase
Order for immediate shipment from stock. Ref: http://www.us.endress.com/e-direct

Does your company have other ways to assist the buyer in selecting the right instrumentation? Yes,
there are many other FREE Endress+Hauser Technical Resources available:
• Theory & Practice of Level handbook
• Food & Beverage handbook
• Digital Communications handbook
• Time of Flight level selection guide
• Coriolis mass flowmeter engineering guide
• Applicator online product selector
• Free Data Acquisition software (download ReadWin 2000)
• Water/Wastewater applications Engineering CD-ROM
• Instrument Management Solutions program. Download document SD 013
• Flow Handbook

12
Innovations
Endress+Hauser sets the industry standard for measurement innovation. To achieve this distinction, we invest
twice the industry average (approximately 10 percent of annual sales) in the development of new products.
This aggressive investment philosophy has led to our continuous introduction of many significant ”firsts” in the
measurement technology.

For instance, Endress+Hauser pioneered the development of frequency shift tuning fork technology, eliminating
many problems associated with other approaches to tank level measurement. Our patented bimorph
piezoelectric design enables a very small sensor to provide exceptional reliability.

We introduced the first dual, straight tube Coriolis mass flowmeter, solving problems our customers had with
drainability, vibration, and installation. And in 1997, Endress+Hauser further advanced flow measurement with
the introduction of the Promass I, the first single, straight tube, ”fit-and-forget” Coriolis mass flowmeter. The
device’s patented TMB (Torsion Mode Balanced) system provides stable, reliable measurement independent of
process conditions.

Endress+Hauser is the largest global producer of industrial pH electrodes and the only company in the world
with fully automated processes for glass blowing, assembly, and testing. This capability ensures a more
repeatable and reliable sensor than is available from any other supplier.

Endress+Hauser’s patented ceramic pressure-sensing diaphragm resists scratches, dents, and corrosive
chemicals. This sensor requires no fill fluid, and therefore virtually eliminates temperature error.

These are just a few examples of Endress+Hauser’s clear leadership in innovation that give our customers
the confidence they have aligned themselves with an instrumentation supplier at the leading edge of process
automation.

Endress+Hauser Honors Inventive Genius

It was innovation that made Endress+Hauser big. Innovation shaped the beginnings when
the company started replacing involved and expensive manual level monitoring with the new
capacitance level measurement from a small room in 1953. Innovation is still the drive behind the
development from a supplier of instrumentation to a solution provider in automation technology.

Endress+Hauser’s 50-year success story has been shaped by innovation and innovators. In 2000, the company
started the Patent Rights Incentive Program to further strengthen its employees incentive to use their creative
potential to the fullest. ”E+H is one of the few medium-sized companies to maintain such a proactive patent
policy,” says CEO Klaus Endress. He thinks it is possible to further increase the rate of innovation - the basis of
the company’s constant growth.

The group filed patent applications for 157 inventions in 2003 – the highest number in company history. These
are 26 applications more than during the previous year and almost three times as many as in 1999 when the
targeted promotion of proprietary rights was started with the ”Patent Rights Incentive Program”. In 2003,
Endress+Hauser employing slightly less than 6,000 employees filed one patent application for approximately
every 38 employees.

The highlight of the Innovator Gathering is the announcement of the winner of the Patent Rights Incentive
Award: it is awarded for the most significant patents granted in the previous year.

The new developments of Endress+Hauser also gain attention beyond the company confines, however. Two
renowned innovation awards go to employees of Endress+Hauser. The company received a ”Sensor Innovation
Award 2003” bestowed by the ”AMA Association for Sensor Technology”. The prize is awarded for the
integration of viscosity measurement into the tried and tested Promass I flowmeter which is developed and

13
constructed at Endress+Hauser Flowtec AG in Reinach (Switzerland). Viscosity - a fluid’s resistance to flow
- can provide a wide range of information on the product quality and processes. The award was presented May
14 within the framework of the international trade fair ”Sensor 2003” in Nuremberg.

The organizers of the trade fair ”Automation Europe - Optimation Europe” awarded Endress+Hauser the ”Prix
Leonard” (named after Leonardo da Vinci) in the category of communication technology. The award was given
for the new Fieldgate FXA 520 web server from Endress+Hauser Maulburg GmbH which makes measured
values available around the globe via the Internet. As a result, vendors can be kept up to date on inventories for
supply chain management, or service technicians can diagnose instruments from a remote site to troubleshoot
specific issues.

Awards
Listed below are a few of the awards Endress+Hauser has received.

Excellence Award from IAN Magazine: Temperature Transmitters, PROline Prowirl 77

Control Magazine’s 2004 Readers’ Choice Awards: In Control Magazine, Endress+Hauser was listed as a
top supplier in their annual Readers’ Choice Awards of the best technologies and service. Of the 65 categories
in the survey, Endress+Hauser rated high in the 13 categories below.
• Coriolis Mass Flowmeter
• Magnetic Flowmeter
• Ultrasonic Flowmeter
• Open Channel Flowmeter
• Vortex Flowmeter
• Flow Switch
• Electrical Property-Based Level Gauge
• Inventory Grade Level Gauge
• Contact Radar Level Gauge
• Non-Contact Radar Level Gauge
• Ultrasonic Level Gauge
• Point Level Switch
• Float Displacer Level Gauge

Each person surveyed was asked to identify by name the best supplier, in their opinion. Therefore each reader
based their responses on personal experience. Additionally, readers are asked to rate each company’s customer
service. Endress+Hauser received high ranking in this portion of the survey.

Promass 83I wins 2003 Innovation Award from Flow Control magazine: The readers of Flow Control
magazine voted Endress+Hauser’s flowmeter, Promass 83I, to receive the Flow Control Innovation Award
2003 for most innovative product of the year. This is the second innovation award for the straight-through
single tube Coriolis meter with direct viscosity measurement. Promass 83I is the first mass flow device which
is able to measure the viscosity of the fluid in-line, therefore delivering a broader range of data than any other
industrial flowmeter.

Viscosity measurement of process fluids is of vital importance in many industries. Its application in Promass
83I is based on patented technology developed by the R&D engineers of Endress+Hauser Flowtec in Reinach,
Switzerland. Coriolis flowmeters measure mass flow and density directly with high accuracy. ”We have
succeeded in using the torsional movement of the measuring tube to additionally measure the viscosity of
the fluid,” explains Dr. Gerhard Jost, Managing Director of Endress+Hauser Flowtec.” This means that the
additional measurement requires no additional installation and that it doesn’t influence the production process
in any way. This is a great advantage for our customers.” The robust design, vibration immunity, long term
stability, as well as an easy to clean hygienic design are advantages of the Promass I Coriolis meters. Combined
with the multivariable functionality, this enables significant reduction in installation and maintenance costs.

14
Glass-free pH Sensor wins Innovation Prize from ”Innovation Trophies” competition: The glass-free
pH sensor TopHit from Endress+Hauser has won first prize in the ”Equipment and Process” category of the
”Innovation Trophies” competition. The prize was awarded by a jury of experts from the agriculture and food
industries and by the specialist press on the occasion of the CFIA in Rennes, France.

The voters paid tribute to this innovative pH measurement method, which uses the IsFET principle. Unlike
conventional pH sensors, the sensor does not require any glass. This excludes any risk of the glass breaking
during operation - a decisive advantage in the Food and Beverage industry. Another advantage is the very
short response time of the sensor. This is clearly evident, in particular when using cooled media because glass
electrodes react very slowly under these conditions.

The TopHit measures the pH value using an IsFET chip (Ion-sensitive Field Effect Transistor). This chip is
integrated into a sensor body made of PEEK, a mechanically and chemically stable material, which is approved
for applications in the food and pharmaceutical industries. All materials used are FDA-listed, non-toxic in
accordance with FDA 21 CFR and even fulfill the criteria regarding how appropriate they are for sterilization
and cleaning according to EHEDG. The sensor has the same dimensions as a conventional pH glass electrode
and can, therefore, be used with all commercially available assemblies.

Exposure via Magazine Articles and Reports

ARC CLIENT REPORT (By ARC Advisory Group) September 2003: Endress+Hauser Leading
Through Focus & Innovation: Visit www.arcweb.com/research/pdfs/EHReport2.pdf for a complete copy of
this report.

ARC Strategies (By ARC Advisory Group) Nov. 2003: Need for Business Knowledge Transfers the
Role of Field Devices. Visit www.us.endress.com/ARC.

Giving coriolis the gas: Request a reprint of this article from FOOD PROCESSING, May 1999

Temperature Control of a Sterilization Process: Request a reprint of this article from the April 2002 issue
of FLOW CONTROL.

TOF technologies offer flexible, cost-effective measurement solutions: Request a reprint of this article
from the November 2000 edition of CONTROL SOLUTIONS.

Compact Level Switch Awash in Options: Request a reprint of this article from CONTROL magazine
October 1999.

Open Control Solution Helps Customer Achieve Economic, Secure Process Sequences: Request a
reprint of this article from FIELDBUS REPORT, Volume 1.2.02 (www.fieldbus.org).

Measuring Viscosity with Coriolis Flowmeters: Article originally published in the April 2003 issue of
CONTROL magazine. See article on next page.

15
16
Introduction to Basic Measurement
Technologies
Level: RF Capacitance Measurement
Parallel Plate
Capacitance level measurement systems take advantage of the Capacitor

dielectric constant in all materials to determine changes in level. d

d
A capacitor is no more than a pair of conductive electrodes, or E A
plates, with fixed spacing and a dielectric (process material) A

between them. In the most common applications, the probe

element (a metal rod or cable) serves as the active plate, while
the process vessel serves as the ground plate. When the “empty
space” or air in the vessel is replaced by the process material, the
E
capacitance electronics register the change in capacitance. This A = Plate area
change is converted to an electrical signal and used to provide an E = Dielectric constant of material
d = Distance between plates
output from a point or continuous level system. Level switches and
continuous level measurements can be accomplished with the right probe configurations and electronics.

Level: Conductive vs. Nonconductive

In the simplest capacitance level measurement system, the dielectric material is the process material, which
is nonconductive. The capacitance probe has no insulation. In this case, introducing a conductive material
between the plates will “short” the plates together, nullifying the ability to measure capacitance. In continuous
level applications with conductive process material, the sensing probe will be insulated, usually with Teflon®.

With conductive material the process fluid is grounded by virtue of its contact with the vessel wall, which
serves as a ground plate. This brings the ground plate into contact with the insulated probe, leaving the plates
separated only by the thickness of the probe insulation which serves as the dielectric material. In this case,
the rising process material does not increase the capacitance by inserting itself between the plates; it increases
capacitance by bringing more of the ground plate in contact with the probe insulation. Such capacitance
increases are easily calculated. The measurement becomes independent of changes in the process material’s
dielectric constant.

For our purposes, water-based fluids and acids may always be characterized as conductive. Nonconductive ma-
terials include hydrocarbons, oils, alcohol, dry solids, etc. When this distinction is not clear, a good numerical
criterion is that materials with a relative dielectric constant of 19 or more, or a conductivity of 20
micromhos or more, may be considered conductive.

Level: Vessel Construction

A “vessel” may fit into one of two groups. The first group consists of vessels with metal interiors that come in
contact with the process material. The second group is made up of fiberglass or plastic walls, or metal tanks
lined with rubber, glass, or other non-conductive materials. The second group will require something other
than the vessel wall to be the ground plate. Normally, this second plate is provided by Endress+Hauser as an
integral part of the probe (ground tube).

Teflon is a registered trademark of DuPont.

17
Level: Vibration Level Switch
Amplitude Shift Tuning Fork
A simple, but effective level measurement technology uses the concept of a vibrating tuning fork. The sensor
detects the level of solids with a freely oscillating tuning fork. The electronics drive a piezoelectric crystal
system that causes the fork assembly to vibrate. Level is detected by the materials damping the vibrations
of the fork. The natural resonance is approximately 120 Hz.

The fork is installed through the top or side wall of a vessel at the point where level detection is desired. As the
fork becomes covered with material, the vibration stops, causing a switch point for relay output. Level can also
be detected as it decreases. As the forks become uncovered by material, they begin to vibrate, causing a switch
point to occur. The tuning fork is typically used in solids applications, such as polystyrene granules, powdered
milk, plastic granules, sawdust, shavings and flour.

Frequency Shift Tuning Fork

The frequency shift tuning fork is vibrated by a patented bimorph piezoelectric drive electronics at about 1000
Hz. As the tuning fork is progressively covered by a liquid or slurry, there is a corresponding shift in frequency.
This shift is monitored and, at an appropriate change in frequency, the switching logic is activated.

Changes in the amplitude of the tuning fork vibrations are not measured and can be ignored. This provides
protection against buildup, gas bubbles and turbulence. Materials with varying density, viscosity, foam,
suspended particles and composition changes do not affect the switch point of the
tuning fork. The frequency shift tuning fork is typically used in liquid applications,
such as syrups, sauces, slurries, and oils.

Level: Ultrasonic Level Measurement

Ultrasonic continuous level measurement involves no contact with the measured
material, making it ideal for applications in hostile environments. Ultrasonic
measurement is versatile and commonly used for continuous, non-contact
measurement of liquids, slurries and solids. Calibration is independent of process
material. A tank with an ultrasonic system can be emptied and then filled with a
different material and the level reading will still be accurate.

In ultrasonic level measurement the operating principle is based on the measurement of the travel time of a
sound signal transmitted from and received by the same sensor after reflection from the liquid or solid surface.
The travel time of a sound pulse is a direct measure of the height of the material in a silo or tank. The distance
in air traveled by the pulse in feet is equal to the travel time in seconds multiplied by the speed of sound in feet
per second. Ultrasonic will not work in vacuums or gasses other than air. Signal process techniques, including
temperature compensation and the rejection of false echoes
returned by tank obstructions, are used to maintain the integrity of the
level information.

Level: Radar Level Measurement

Empty

Radar level measurement is designed for challenging applications requiring

Full

non-contact, continuous level measurement. Radar level instruments

are ideal for dynamic process applications with rapid level changes or
agitator blades involving liquids and slurries. The radar systems from
Process Level

Endress+Hauser are suitable in areas of high temperature or pressure, in

the presence of gas vapors, vacuum, turbulence, or dust.

18
Endress+Hauser uses the pulse time-of-flight (PTOF) principle. Short radar pulses are
emitted towards the material from an antenna. These pulses are reflected from the
material surface and detected by the same antenna, now acting as the receiver. The
distance to the material surface is proportional to the run time of the radar pulse.

The system operates in a frequency band assigned for industrial, scientific and medical
applications. Its low beam power allows safe installation in metallic and nonmetallic
vessels, with no risk to humans or the environment. This technology does not require an
FCC site license and can be used without restrictions.

The newest Endress+Hauser radar instrument, Levelflex, is a “downward-looking”

time-of-flight system, which measures the distance from the probe mounting (top of silo)
to the material level. An electrical impulse is launched and guided down the probe or
cable, which acts as a surface wave transmission line. When the surface wave meets a discontinuity in the
surrounding medium (a sudden change in dielectric constant), it is partially reflected. The reflected impulse
travels back up the cable probe to the pulse sampler where it is detected and timed.

Each point along the probe is sampled for its pulse reflection behavior. The information accumulated over the
sampling cycle is captured and passed on to the signal processing, which identifies the signal produced by the
change in dielectric constant at the air / product interface. The Levelflex can measure level in both liquids and
solids.

Flow: Electromagnetic Flow Measurement

Electromagnetic flowmeters measure the volume flow rate of electrically conductive fluids. The measuring
sensor consists of a lined pipe, an electromagnetic coil, and corrosion-resistant electrodes (not to all process
materials). When the conductive liquid or slurry passes through the magnetic field (produced by the magmeter
electronics), it generates a voltage proportional to the average velocity of the
material. It is based on Faraday’s law of induction: if a conductor moves
within a magnetic field, a voltage will be induced therein. Liquid media
can be accurately measured with conductivities of 1 µS/cm and above.

The voltage induced by the flowing fluid is proportional to the flow rate.
The measuring electrodes detect the voltage signal which is sent to an
amplifier where it is digitized and communicated to the transmitter. The
transmitter processes the signals and outputs current and pulse signals
which are used for totalizing, pump control, limit values, batch functions,
etc.

Flow: Coriolis Mass Flow Measurement

The measuring principle is based on the controlled generation of Coriolis forces. The sensing meter contains a
flow tube(s), which in the absence of flow, the inlet and outlet sections vibrate in phase with each other. When
liquid is flowing, inertial (Coriolis) forces cause a phase shift between inlet and outlet sections. Two sensors
measure the phase difference, which is directly proportional to flow.

The amplitude of the Coriolis force depends on the moving mass

(process material), its velocity in the system, and therefore its mass
flow. The flowing material causes the tube(s) to oscillate, acting like
a tuning fork. As the mass flow increases, the phase difference also
increases. The oscillations of the measuring pipe(s) are determined
using electro dynamic sensors at the inlet and outlet of the measuring
tube assembly. The measurement principle operates independent of
temperature, pressure, viscosity, conductivity or flow profile.

19
The Promass I has a full bore, straight-through, single-tube design which operates somewhat differently
than the dual-tube design. In order to maintain balance for flawless measurement, a patented Torsion Mode
Balanced (TMB) system is used. By exciting an eccentrically located, counter-oscillating pendulum mass, the
single tube system provides accurate measurement, even with changing process and ambient conditions.

The sensor signals are processed by the transmitter electronics and provide the user with various outputs to
monitor or control the process.

The Promass measuring system is used wherever mass flow measurement is critical in mixing and batching
of raw materials, process control, measurement of quickly changing densities and control of product quality.
Coriolis meters can measure mass flow, volumetric flow, density, temperature, and/or viscosity as well as
special density units such as percent solids, °BRIX, and other units of measure.

Flow: Vortex Shedding Flow Measurement

The vortex sensor measures flow rate using the Karman Vortex Street principle. As fluid flows past a bluff
body, vortices are produced on alternate sides of the body. The frequency at which these vortices are
produced (or shed) is directly proportional to the flow rate and is independent of fluid density, viscosity,
pressure, or temperature.

The principle function of the flowmeter is threefold: the bluff body disrupts
the fluid stream creating vortices, the DSC sensor and front-end electronics
detect the shedding vortices and process a pulse output signal, the
electronics convert the signal to a useable scaled output signal. The DSC
(Differential Switched Capacitor) sensor improves the signal-to-noise ratio
and eliminates the effects of vibration on the measuring signal.

The DSC sensor detects the vortices shed by the bluff body. The lower
sensor section contains the capacitance pickup system which projects into
the radial bore of the bluff body.

Vortex pulses acting on the tongue mistune the capacitors and this change is detected by the capacitor circuit.
The elastic behavior of the carrier rod and tongue are matched by computer design which effectively cancels
any pipe vibration acting on the sensor. The carrier rod and tongue move in absolute synchronism regardless
of the vibration axis, including rotational vibration. By eliminating any external effects of vibration, only the
vortex pulse signals are processed by the electronics.

The Prowirl vortex measuring system from Endress+Hauser is ideal for liquids, gases, and steam. Applications
for oxygen, nitrogen, cryogenics, and solvents are well within the measuring techniques of the vortex system.

Flow: Ultrasonic Flow Measurement

The ultrasonic flow system is a non-intrusive, externally mounted measuring system which uses ultrasonic
sound waves to measure the flowing fluid in a pipeline. The Prosonic flow system operates on the principle of
transit time differences. An acoustic signal (ultrasonic) is transmitted
from one sensor to another.

The time (transit) that the signal requires to arrive at the receiver
is then measured. According to physical principles, the signal sent
against the direction of flow requires longer to return than the signal
in the direction of flow; therefore, the difference in the transit time
is directly proportional to the velocity of the flow. The transmitter
converts the measured values supplied by the sensor(s) into
standarized output signals.

20
The DMU Prosonic Flow sensors (clamp on version) are mounted directly onto existing piping. Isolating or
opening the piping is not required. The system is ideal for bidirectional measurement of pure or slightly dirty
liquids. The Prosonic Flow is especially suitable when retrofitting equipment as no interruption of the process
is necessary.

Endress+Hauser offers insertion sensors which extends ultrasonic flow measurements to piping with material
of insufficient sonic conductivity. It is equally suitable for retrofitting, but requires a process interruption for
installation. Once installed, the sensors can be replaced without process interruption. Sensors are available as
single path (2 sensors) or dual path (4 sensors). Dual path systems offer measurement reduncancy, improved
linearity and reduces requirement for upstream straight piping.

Pressure: Gauge/Absolute Pressure Measurement

Pressure measurement for gauge, absolute, vacuum and compound are based on two technologies; capacitance
ceramic sensors (for up to 600 psig) and polysilicone sensors (for up to 6000 psig).

Ceramic Sensor 1

The operating principle of the ceramic sensor is based on capacitance 2

technology. As pressure is applied to the ceramic diaphragm, the

measuring capacitor deflects by a maximum of less than 0.001 in. A
change in capacitance proportional to pressure is measured between
Ceramic
the substrate electrode and the measuring (diaphragm) electrode. The Sensor
electronics convert this differential capacitance into a useable output
signal.

Using thick-film technology, the surfaces of the measuring capacitor are � Ceramic substrate
� Ceramic diaphragm
gold-plated and directly connected to the laser-trimmed hybrid electronics.
With no diaphragm seal oil, this direct pressure signal conversion � Polysilicon measuring element
also ensures an extremely high measuring accuracy, independent of � Channel with filling fluid
temperature, even at lower pressure ranges. � Metallic separating diaphragm
� Flush mounted and welded diaphragm

The actual measuring range is determined by the

thickness of the ceramic diaphragm which, with
overload, stops on the ceramic substrate without 3

sustaining damage. When conventional transmitters 4

5
with metal diaphragms are exposed to high pressure, 3

they tend to deform, which results in a pressure 4

measuring shift. By comparison, the ceramic sensor 6

from Endress+Hauser has an overpressure rating of up Polysilicon

to 100 times the measuring range. Sensor

Polysilicone Sensor
The polysilicone sensor incorporates insulated thin film strain gauges. Substrate

The line pressure deflects the separating diaphragm and the filling fluid Diaphragm

transmits the pressure to a resistance bridge. The bridge output voltage, Electrodes

which is proportional to pressure, is then measured and processed.

Fritted glass

The polysilicone sensor offers a wide temperature range, a small and easily Temperature Sensor
compensated temperature coefficient and long-term stability. Its good
elasticity properties ensure high reproducibility, low hysteresis and fourfold Ceramic Sensor
resistance to overload.

21
Pressure: Differential Pressure Measurement
Differential pressure sensors are available in two versions; single chamber ceramic
sensors (for up to 1200 inH2O) or silicon sensors (for up to 580 psi).

The ceramic sensor consists of a substrate and two diaphragms. The diaphragms and
substrate constitute two measuring surfaces and are connected by a capillary. Silicone
oil, mineral oil or inert oil serves as the filling fluid in the capillary. A differential
pressure-proportional change in the capacitance is measured by the electrodes on the
ceramic substrate and diaphragms.

The silicon measuring sensor is comprised of a silicon diaphragm which has Measuring Element

pressure sensitive thin-film resistors. The differential pressure acting at the Silicon Diaphragm

isolating diaphragms is transmitted to the measuring element by silicon or

inert oil. The silicon diaphragm deflects accordingly causing a change in Isolating Diaphragm

resistance which is measured and processed by the transmitter electronics.

The silicon sensor offers a wide temperature range, a small and easily
compensated temperature coefficient and long-term stability. Its good
Silicon Sensor
elasticity properties ensure high reproducibility and low hysteresis.

Pressure: Hydrostatic Pressure Measurement

Hydrostatic level measurement provides both continuous and limit control of liquids and pastes. Together with
an appropriate transmitter, they can be used to determine level, volume, differential pressure, product weight,
density and can be integrated into various automation systems.

The weight of a column of liquid generates a hydrostatic pressure. At constant

density, the hydrostatic pressure is a function of the height of the liquid only.

The core of the system is the CONTITE™ chrome/nickel resistive measuring

cell. It is hermetically sealed and fully protected against external influences.
No condensation, dust or moisture can penetrate or affect the measurement
process. The measuring element is a copper beryllium alloy diaphragm on
which there is a thin film measuring bridge. It is mechanically connected
to the measuring diaphragm and embedded in a small amount of oil
(approximately 3 drops) between the process and the measuring diaphragm.

The atmospheric pressure acts on the measuring cell through a pressure compensation system and thus is self-
compensating. An overload substrate protects the measuring cell from pressure peaks to 20 times those of the
nominal rating (maximum 360 psig). This ensures that accuracy remains unaffected. The measuring cells
cover a pressure range from 15 inH2O to 58 psig. Vacuum can be measured to 1.7 psia.

Analysis
Water, the most abundant substance on earth is used throughout the industrial world as a critical substance in
the manufacturing processes. From the Chemical, Oil, and Gas Industries to the Automotive Industry, within
the Pulp and Paper Industry to the precise manufacturing environment of a Semiconductor plant, water is
there, providing the medium in which many products are made, modified, and/or cleaned. The purity of our
drinking water has increasingly become a matter of public concern. Most drinking water supplies today require
special treatment before it can be distributed and utilized. This is to eliminate possible toxic and infectious
contaminants and make it safer for human consumption.

22
Endress+Hauser offers a full line of analytical systems important to different interests and industries. Examples
of available technologies and industries include:
pH Environmental
Oxidation/Reduction (ORP) Corrosion
Conductivity Scaling
Dissolved Oxygen Power
Chlorine Disinfecting
Turbidity Dissolved Solids

Analysis: pH
pH is the measurement of hydrogen ion activity. It is measured on a scale of 0 to 14, where 0 is extremely
acid and 14 is extremely alkaline. The mid point of 7.0 pH is distilled water. It is the most widely used liquid
analysis measurement, and is found in all industries. Used to determine the degree of acidity or alkalinity of a
sample, pH measurement is a number that is directly related to the ratio of H+ (hydrogen ion) and OH- (hydroxyl
ion) concentrations in a solution.

Endress+Hauser offers two groups of pH electrodes. CPF compact electrodes, which are inserted directly into
the process, or CPS glass electrodes which are placed in a separate holder.

Analysis: ORP
ORP (Oxidation-Reduction Potential) measurements are used to monitor chemical reactions, quantify electron
activity or determine the oxidizing or reducing properties of solutions. ORP is related to pH in that it utilizes
a similar measuring system, and delivers millivolts, as does pH. ORP is a specialized measurement that can
follow the progress of a chemical reaction that involves the loss and gain of electrons (Oxidation or Reduction)
between species in solution. ORP only measures in millivolts, whereas pH measurements are related to a scale.
As in pH measurement, the electrodes are of the same type.

Analysis: Conductivity
Conductivity is a common measuring technique. The range of conductivity is wide, from the purest water to
the high conductivity of acid and alkali concentrations. Conductivity is a straightforward and reliable way to
determine the purity of water, or the concentration of an acid or alkali.

The principle of conductivity measurement for analysis is defined as the ability of a solution to conduct an
electrical current between two electrodes. In a solution, the current flows by ion transport. Therefore, the
higher the ion concentration, the more current can flow. Chemical compounds which produce conducting
solutions are called electrolytes.

Endress+Hauser offers two basic types of sensors for conductivity measurement. The contacting (conductive)
sensor and electrodeless (inductive) sensor.

Analysis: Dissolved Oxygen

Dissolved oxygen (DO) is the term commonly used in liquid analytical work for the measurement of the amount
of oxygen dissolved in a unit volume of water. It is an important indicator of the degree of usefulness of a
sample of water for a specific application. The process requirements of a given application determine the level of
dissolved oxygen that can be tolerated.

Water, by its nature, is an excellent solvent not only for compounds which dissociate into ions, but also for
dissolved gases, including molecular oxygen. Different samples at the same temperature, saturated with

23
oxygen, can have different concentrations of oxygen. They all may be 100% saturated, but have different
concentrations of oxygen.

The primary application for parts-per-million (ppm) dissolved oxygen systems is measurement and control in
aeration basins used in aerobic digesters in wastewater treatment plants. Correct levels of oxygen must be
maintained to nourish the bacteria that are used to digest the waste.

Endress+Hauser offers a single sensor style for measuring dissolved oxygen. The membrane covered sensor
provides a sealed system which measures the oxygen molecules transferred through a gas permeable membrane to
the electrodes.

Analysis: Chlorine
As a common last step of water treatment, a chlorination takes place, not only to destroy remaining bacteria but
also to prevent the growth in the water pipe system which delivers clean water to households and industrial
locations. Chlorine is a building block for nearly all chemical processes. It plays a vital role in the health of the
population and in maintaining a clean and safe environment.

The chlorine measuring sensor is similar to the dissolved oxygen sensor, in that it is a membrane covered
sensor. The chlorine sensor only allows hypochlorous acid molecules to diffuse through the membrane to react
at the electrodes. Detected hypochlorous acid is a proportion of the active chlorine, which acts as a depolarizer
at the cathode after diffusion by the membrane.

Analysis: Turbidity
Water can contain solid matter of many different sizes. Some suspended solids will be large enough and heavy
enough to settle to the bottom of a container if the water is left to stand. Other solids which are finer will
remain in the water above the settled matter. These solids are called turbidity. Since the individual particles
are often too small to see, turbidity usually appears as a cloudiness or haziness to the water; therefore, turbidity
describes the relative clarity of water.

Turbidity uses an optical measurement to measure the content of undissolved particles in fluids, mainly water.
A beam of light passing through a sample of water is absorbed and scattered by the particles, thereby permitting
a qualitative statement to be made concerning the water quality. Turbidity measurement is unable to provide
any direct conclusions as to the number of particles contained in the water.

Endress+Hauser turbidity sensors use the 90 degree scattered light method with a measuring frequency in the
near infrared range. Digital filtering with excellent interference signal suppression and sensor self monitoring
ensure measurement reliability.

Temperature
Of all process variables, Temperature is the one with which people have the most personal familiarity. Yet,
many of the measurement issues are not clearly understood by the average person. Further, the concepts of
temperature and heat are often confused.

Fundamentally, temperature is indicative of the average amount of kinetic energy in a group of molecules. That
is, it is a direct indication of the average amount of molecular motion in the studied object. Even the human
senses detect temperature changes, and can sense which of two objects has the higher temperature. Yet
temperature is not a measure of the amount of heat (or heat energy) contained within an object. An iceberg,
although colder than a lit match, contains vastly more heat than a lit match. Heat may be thought of as the
sum of all the kinetic energy of all the molecules-in-question. If temperature tells us nothing about the energy
contained in an object, what then does temperature tell us?

24
Our concepts of “colder” and “warmer” are directly related to relative temperatures. And temperature tells
us one very important thing—which way heat will flow. When two bodies are in contact, heat (or energy),
always moves from a body of higher temperature to a body of lower temperature*. Two simple bodies in contact
and left alone, will eventually reach the same temperature.

The expression of a measured temperature value may be in any one of several different “temperature scales”.
That is, there are different temperature “units”, all called “degrees”. The specific unit used is indicated by
the “type” of degree stated. All temperature scales seek to create a one-to-one correspondence between the
indicated temperature value and a specific level of molecular activity. The most commonly used scales are the
Celsius (formerly Centigrade) and Fahrenheit. These linear scales have somewhat arbitrary “starting points”
for what they consider to be “zero degrees”. In contrast the Kelvin and Rankine scales set zero degrees to
correspond to the theoretical “absolute zero” where all molecular motion would cease. These latter scales are
a bit more convenient when the goal is to relate a temperature measurement directly to heat content or kinetic
energy, since the temperature is directly proportional to both, and requires no offset to the more arbitrary zero
points of the Celsius and Fahrenheit scales.

What is it, fundamentally, that causes a temperature sensing device (or even your skin) to get a “reading” of
the temperature? At the molecular level, it is the result of the aggregate momentum transferred to the sensing
device by all the collisions of moving molecules.

In industrial processes, the measurement of

temperature is not only critical for numerous
reasons, but it is also the single most common
process variable measured.

Although there are several sensor types used to

transducer sensed temperature into a measurable
and useable electrical signal, the vast majority
used are one of two types---the “RTD” (Resistive
Temperature Device), or the Thermocouple.

*Exception: using a clever technique, a powered device called a ”heat pump” can extract heat from a colder object, cooling it even further,
and pass that heat into a warmer object, raising its temperature.

25
Endress+Hauser Product Offering
Services
Endress+Hauser‘s Service Department is dedicated to providing the service that you need now and in the
future. Our objective is to provide total support to you and your instruments, and to keep your plant working
efficiently, seven-days-a-week, 24-hours-a-day. See inside back cover for more details.

Help Desk
Technicians and Specialists available to help troubleshoot applications and installations. Call 800-642-8737.

24-Hour Emergency Support

Emergency phone support 24-hours-a-day, 7-days-a-week. Call 800-642-8737.

Spare Parts & Consumables

Replacement parts, boards, modules, sensors and transmitters as well as consumable items such as pH electrodes, chart paper, pens, etc.

Factory Repairs
Trained factory technicians perform instrument repairs and recalibration in the Greenwood, IN facility.

Field Service
On-site service to help troubleshoot and diagnose instrument problems. Remote Maintenance Services also available.

Tools and Software

Specialized hardware and software components to allow for effective programming, diagnostics, data visualization and analysis.

Start-up
On-site support to help get your new instruments commissioned properly.

Maintenance Agreements
Annual agreements for Preventative Maintenance work on a periodic basis

Calibration
Certified factory rigs for traceable calibrations, as well as on-site capabilities for various technologies.

Maintenance Training
Courses at the Factory or On-site to teach proper maintenance techniques for operations personnel.

Technology Training
Courses at the Factory or On-site to teach measurement technologies for engineering personnel.

System Solutions
Assistance with design and selection of proper digital network devices for Fieldbus™, Profibus®, HART®, and other protocols.

Instrument Management Solutions

Site Audit service which includes a comprehensive Maintenance Plan.

e-Services W@M
On-line functions to provide vast amounts of instrument information via the Internet.

26
Pressure Products
For process pressure, differential pressure, level and flow:

Cerabar T Cerabar M Cerabar S

Description

Gauge/Absolute Pressure Gauge/Absolute Pressure Gauge/Absolute Pressure

Application Process Pressure Process Pressure, Level Process Pressure, Level
Measuring Spans 40 inH2O to 600 psi 4 inH2O to 6000 psig 2 inH2O to 10500 psig
Fixed Ranges 30 mmHg to 6000 psia 15 mmHg to 10500 psia
Pressure Sensor Ceramic up to 580 psi Ceramic up to 600 psi Ceramic up to 600 psi
Polysilicon up to 6000 psi Polysilicon up to 6000 psi Polysilicon up to 1000 psi
Output 4-20 mA 4-20 mA HART® 4-20 mA HART®, Profibus®-PA,
4-20 mA Analog FOUNDATION™ Fieldbus
Process Temperature -5 to 212 °F -40 to 260 °F -40 to 212 °F
600 °F with diaphragm seals 662 °F with diaphragm seals
Accuracy 0.5% Full Scale 0.2% over 10:1 Turndown 0.075% over 15:1 Turndown
Turndown N/A 10:1 100:1

Long Term Stability 0.15% / 12 months 0.1% / 12 months 0.05% / 12 months

Process Connections ½” NPT, ¼” FNPT, G ½”, NPT, Sanitary Couplings, ANSI NPT, Sanitary Couplings, ANSI
Tri-Clamp® Flanges, Flush Mount Ceramic Flanges, Flush Mount Ceramic
Certificates/Approvals CE FM, CENELEC, CSA, 3-A, CE FM, CENELEC, CSA, 3-A, CE
Communications HART® , HART®, Profibus®-PA,
Profibus®-PA FOUNDATION™ Fieldbus

Deltabar S Deltapilot S

Description

Differential Pressure Hydrostatic Pressure

Application Differential Pressure, Level, Flow Level
Measuring Spans 0.4 inH2O to 1200 inH2O; 580 psid 15 inH2O to 1660 inH2O; -13 psi to 60 psig
Pressure Sensor Ceramic up to 1200 inH2O CONTITE™ Measuring Cell
Polysilicon up to 580 psid zero to 60 psig
Static pressure up to 6000 psi -13 psi up to 60 psig
Output 4-20 mA HART®, Profibus®-PA, 4-20 mA HART®, Profibus®-PA,
FOUNDATION™ Fieldbus PFM
Process Temperature -40 to 185 °F; 662 °F with diaphragm seals 14 to 212 °F (275 °F, max. 30 minutes)
Accuracy 0.075% over 15:1 Turndown 0.2% over 10:1 Turndown (optional 0.1%)
Turndown 100:1 10:1

Long Term Stability 0.05% / 12 months 0.1% / 6 months

Process Connections ¼” to 18” NPT, Extended Diaphragm Seal, 1½” NPT, Sanitary Couplings, ANSI Flanges,
Sanitary Couplings, Flush Mount Ceramic Tri-Clamp®; Weld Spud
Certificates/Approvals FM, CENELEC, CSA, 3-A, CE FM, CSA, 3-A, CE
Communications HART®, Profibus®-PA, HART®
FOUNDATION™ Fieldbus Profibus®-PA

27
Level Products
For limit detection of liquids and solids.

Minicap Soliphant T Liquiphant FTL 20

Description

Capacitance Amplitude shift tuning fork Frequency shift tuning forks

Solid  
Liquid  
Temperature Range -40 to +250 °F -40 to +300 °F -40 to +212 °F
Maximum Overpressure 360 psig 230 psig 580 psig
Maximum Probe Length Rod fixed 5.5” Fixed 8.5” Fixed 2.5”
Cable 236 in.
Minimum Connection 1” NPT 1½” NPT ½” NPT
Maximum Viscosity 10,000 cp
Dielectric Constant ≥ 1.6
Maximum Grain Size 1.2” 0.4”
Certificates FM, CSA CSA, CSA US
Relays  
PNP Output   

Liquiphant T Prosonic T Soliswitch

Description

Frequency shift tuning fork Ultrasonic Paddle Switch

Solid  
Liquid  
Temperature Range -40 to 300 °F -40 to 176 °F -4 to 176 °F
Maximum Overpressure 360 psig 30 psig -7 to 11.6 psig
Maximum Probe Length Fixed 5” 26 ft. Shaft 23.6”
measuring range Cable 78.7”
Minimum Connection 1” NPT 1½” 1¼” NPT
Maximum Viscosity 10,000 cp
Maximum Grain Size 2.0”
Certificates CSA GP CSA GP FM, CSA
Relays  
PNP Output 

28
For continuous measurement of liquids and solids.

Prosonic

Description

Ultrasonic
Solid 
Liquid 
Temperature Range -40 to 176 °F
Maximum Overpressure 30 psig
Maximum Measuring Range 49 ft.
Minimum Connection 1½”
Accuracy 0.25% measuring span
4-20 mA 

Analysis Products
Sensors and transmitters for analyzing liquids.

CPS 11 CPS 41 CPF 81

Sensors

Parameter pH pH pH
Application Replaceable Electrode with Gel Replaceable Electrode with Compact Electrode
Reference Liquid Reference
Plug TOP 68 TOP 68 TOP 68 (optional)
Maximum Temperature 265 °F 265 °F 230 °F
Maximum Pressure 150 psig at 265 °F 150 psig at 265 °F 145 psig at 175 °F

CLS 21 CUS 41 CCS 140

Sensors

Parameter Conductivity Suspended Solids Chlorine

Application Mid-range Contacting Sensor Wastewater Sensor Industrial Sensor
Maximum Temperature 300 °F 160 °F 110 °F
Maximum Pressure 230 psig at 68 °F 90 psig at 160 °F 14 psig

29
 Liquisys S
CxM 223/253

Transmitters

Parameter pH/ORP, Conductivity,

Turbidity, Chlorine,
Dissolved Oxygen
Instrumentation 4-wire
Installation Field, Panel
Approvals CSA GP
Communication HART , Profibus®-PA, DP
®

Outputs 2 x 4 - 20 mA

Flow Products
For measuring liquids, gases, and vapors.

Dosimass Dosimag Promass

Description

For use as a mass or volume Flowmeter for quick and accurate Coriolis mass flow & density
flowmeter for filling applications flow measurement in batching measurement for liquids and
and filling plants gases—Viscosity measurement as
an option
Nominal Diameters 3/8” - 1” 5/32” - 1/2” 1/24” - 6”
Measuring Range 39,683 lb/hr Flow: 0.016 to 79 gal/min Flow: 0-29,400 lb/min
Density: 0-3 SGU
Measuring Uncertainty Mass flow: ± 0.15% o.r. Volume flow: ± 0.25% o.r. Liquids: ± 0.1% o.r.
or or (± zero point stability)
± 0.3% ± [(zero point stability/ ± 0.5% o.r. ± 1 mm/s Gases: ± 0.35% o.r.
measured value) x 100]% o.r. or (± zero point stability)
or ± 5% o.r.
± 5% ± [(zero point stability/measured
value) x 100]% o.r.

Temperature Range -40 to 257 °F -4 to +266 °F -60 to 660 °F

Process Connection Tri-Clamp®, threaded joint, Tri-Clamp®, weld nipple Tri-Clamp®, Weld Nipple
sanitary connection
Inputs/Outputs Outputs: Outputs: Inputs: 0/4 - 20 mA, Status
Pulse: Passive, max 30V DC/250 mA, Pulse: Open collector (passive) Outputs: 0/4 - 20 mA
a pulse value and pulse polarity can 0 - 30 kHz, 30V DC/100 mA maximum Frequency, Relay
be selected, pulse width adjustable Status: Open collector (passive)
(0.05 mS - 1s) 30V DC/100 mA maximum
Status: Passive, max. 30V DC/ All circuits galvanically isolated
250 mA

Power Supply 24V DC nominal voltage 24V DC nominal voltage 85 - 260V AC, 20 - 55V AC
(20 - 30V DC) (20 - 30V DC) 16 - 62V AC
Certificates FM, CSA FM, CSA FM, CSA

Communication Via FieldTool Via FieldTool HART , Profibus®-PA, Profibus®-

®

DP, FOUNDATION™ Fieldbus,

Modbus

30
 Promag Applicator™ FieldTool™

Description

Electromagnetic flowmeter Flowmeter selection and Innovative configuration and

Nominal Diameters
Measuring Range
Measuring Uncertainty
Temperature Range
planning support software for service PC software. A new age
process measurement of field instrument management
1/12” - 78”
0 - 500,000 gpm
± 0.2% o.r.
-40 to 355 °F

Process Connection Tri-Clamp®

Inputs/Outputs Inputs: 0/4 - 20 mA, Status
Outputs: 0/4 - 20 mA
Pulse/Frequency, Relay
Power Supply 85 - 260V AC
20 - 55V AC
16 - 62V AC
Certificates FM
CSA
Communication HART®
Profibus®-PA
Profibus®-DP
FOUNDATION™ Fieldbus
Modbus

FieldCheck™

Description
Universal signal simulator
with ”intelligence.” Testing
and validation of flowmeters—
universal field verification
and simulation tool for
Endress+Hauser flowmeters
Measuring Uncertainty Input:
Current: ± 5 µA
Frequency: < 0.5 Hz

Power Supply 12V DC

NiMH rechargeable battery

31
Temperature Products
For measuring temperature.
easytemp™ TSM 470 G easytemp™ TSM 470 F easytemp™ TSM 470 P

Description

Compact Thermometer Compact Thermometer Compact Thermometer

Application General purpose Food industry Pharmaceutical industry
Measuring range -60 to +320 °F -60 to +320 °F -60 to +320 °F
Output signal Analog, 4 - 20 mA, 20 to 4 mA Analog, 4 - 20 mA, 20 to 4 mA Analog, 4 - 20 mA, 20 to 4 mA
Power supply 10 - 35V DC, polarity protected 10 - 35V DC, polarity protected 10 - 35V DC, polarity protected
Minimum immersion 1½” ¾” ¾”
Process connection ½” NPT 1”, 1½”, 2” Tri-Clamp® ½” and ¾” Tri-Clamp®
Sensor diameter ¼” sheath ¼”, 3/8” reduced to 3/16” 5/32”

Insertion length 3¼” - 8¼” 2” - 6” ¾” - 2¾”

iTEMP® TMT 127 iTEMP® TMT 128 iTEMP® TMT 121

Description

Rail Mounted Transmitter Rail Mounted Transmitter Rail Mounted Transmitter

Input RTD Thermocouple (TC) RTD/Thermocouple (TC)
Output 4 - 20 mA 4 - 20 mA 4 - 20 mA
Operation Fixed range Fixed range PC Programmable
Certificates FM, CSA, ATEX FM, CSA, ATEX FM, CSA, ATEX

iTEMP® TMT 122 iTEMP® TMT 187 iTEMP® TMT 188

Description

Rail Mounted Transmitter Head Transmitter Head Transmitter

Input RTD/Thermocouple (TC) RTD Thermocouple (TC)
Output 4-20 mA 4 - 20 mA 4 - 20 mA
Operation HART® Fixed range Fixed range
Certificates FM, CSA, ATEX FM, CSA, ATEX FM, CSA, ATEX

iTEMP® TMT 180 iTEMP® TMT 181 iTEMP® TMT 182

Description

Head Transmitter Head Transmitter Head Transmitter

Input Pt 100 RTD/Thermocouples RTD/Thermocouple (TC)
Output 4-20 mA 4 - 20 mA 4 - 20 mA
Operation PC Programmable PC Programmable HART®
Certificates FM, CSA, ATEX FM, CSA, ATEX

32
 RIT 261 TMT 162

Description

Transmitter with Display Field transmitter

Input RTD/Thermocouple RTD/Thermocouple
Output 4 - 20 mA 4 - 20 mA
Operation PC Programmable or HART® HART®
Display type 5 Digit LCD Bargraph
Bargraph
Certificates FM, CSA, ATEX FM, CSA, ATEX (XP/XI)

Recorder and Process Display Products

For recording data.
Eco-Graph Eco-Graph C Memo-Graph Memo-Graph S
Eco-Graph A

FDA 21 CFR
Description Part 11
compliant

Paperless recorder Batch Counter Data Manager Safety Data Manager

Special feature(s) No paper/pens Remote control Application software FDA 21 CFR Part 11
functions packets available. compliant.
Seismic tested IEEE 344 Optimized for multi-
product batch recording
Number of inputs
Analog 3 or 6 0 0 or 8 or 16 0 or 8 or 16
Universal   
Discrete  up to 32 Up to 37 Up to 37
4 control max. 25 Hz Control and count Control and count
4 control/count in A (25 Hz) (25 Hz)
version
Plot or memory storage Internal + floppy Internal + floppy Internal + floppy Internal
ATA Flash Cards ATA Flash Cards
Setpoints 2 per channel 2 per channel 4 per channel 6 per channel with 2 per
channel per product.
20 products
Control relays 3 up to 15 up to 17 up to 17
Analog outputs No No No 4 or 8
Math and/or    
Totalization
Signal analysis    
(Min/Max/Avg)
Communication
RS232 and/or RS485    
Ethernet    
Profibus DP No Optional Optional
Loop power to the Yes Yes Yes Yes
transmitter
Batch functions Yes Optional software Multi-product, multi-
batch
Display type 5” LCD Multicolor 5” LCD Multicolor 5.7” LCD Multicolor 5.7” LCD Multicolor

33
Recorder and Process Display Products
Other products.
Minilog B Alphalog

Description

Data Logger Hybrid Paper Recorder

Special feature(s) Battery powered available IP 54
RS232 communication RS232 communication
Automatic windup;
190 ft. (58 m) paper
Number of inputs
Analog 1 1 to 6
Universal  
Discrete 1 4
Plot or memory storage Paper
Setpoints 2 per channel 2 per channel
Control relays 4
Math and/or Totalization  No
Communication
RS232  
Display type LCD 7 digit LCD Alphanumerics

RNS 221 RN 221N RMA 421

Description

Power supply Active barrier Transmitter

Loop supply 2 1, Ex ia 1
24 VDC, 30 mA
Power supply 20-250V AC/DC 20-250V AC/DC 90-250V AC
18-36V DC
Analog input 1 (Current), Ex 1 (Current, Voltage, Resistance,
RTD, TC)
Analog output 1 (Current) 1 (Current, Voltage)
Relay 2
Mathematic Linearization of the input signal
Communication Integrated HART communication Bi-directional HART transmission. Integrated HART communication
sockets Integrated HART communication sockets
sockets
ReadWin 
Benefits ATEX, FM, CSA Multifunctional; display, power
supply, separate, linearize, switch,
transform

34
 RMA 422 RTA 421

Description

Transmitter Contactor
Loop supply 1/2, Ex 1
24 VDC, 30 mA
Power supply 90-250V AC 207-250V AC
18-36V DC 102 - 127V AC
20-250V AC/DC
Analog input 1/2 (Current) Ex 1 (Current, Voltage)
Analog output 1/2 (Current, Voltage)
Relay 2 2
Mathematic Linearization, +, –, *
Communication Integrated HART communication sockets Integrated HART communication sockets
ReadWin 
Benefits Multifunctional; display, power supply, separate, linear- Displaying the relay status according to NAMUR.
ize, switch, transform. ”Mini” bargraph display.
1 or 2 current inputs, save costs, solve complete
requirement for difference pressure or tank monitoring
application.
Mathematical functions for calculations and average
value.
Small monitoring solutions.
Useful for many small applications in areas of monitor-
ing signals, adding signals, finding average tempera-
ture, level, pressure, linearization of non-standard
sensor signals, adding, subtracting energy in different
loops, etc.

35
 RID 261 RIA 250 RIA 251

Description

Profibus-PA display Digital display module Digital loop-powered display

(panel mount)
Loop Supply 
Power Supply Profibus PA 90-253V AC Loop powered, Ex
18-36V DC
Analog Input 1 (Current, Voltage, RTD, TC) 1 Current
Analog Output 1 (Current, Voltage)
Relay 2
HART® suitable  
Profibus® 
Dimensions (WxHxD) 3.98” x 3.98” x 2.36” 1.89” x 3.86” x 5.91” 1.89” x 3.86” x 3.54”
(100 x 100 x 60 mm) (48 x 96 x 150 mm) (48 x 96 x 90 mm)
Benefits ReadWin 2000 operation Less voltage drop in current loop
Approvals IP 65 (front) / IP 20 IP 65 (front) / IP 20
ATEX/FM/CSA
Applications Linearization (up to 32 points) Display, power supply, separate,
for the input signal (e.g. tank linearize, switch, transform
applications)
Short Description Display of measured values.
Display of limit violations.
Profibus

RIA 261/RIT 261 RIA 450

Description

Digital loop-powered display (weatherproof) Process display

Loop Supply 
Power Supply Loop powered, Ex 90-253V AC
18-36V DC
Analog Input 1 Current / 1 RTD, TC 1 (Current, Voltage, RTD, TC)
Analog Output
Relay 4
HART® suitable  
Profibus®
Dimensions (WxHxD) 6.89” x 3.15” x 2.36” 3.86” x 3.86” x 6.61”
175 x 80 x 60 mm (96 x 96 x 168)
Benefits Use in direct sunlight, display with backlight Multi-colored display with bargraph monitoring the
signal of active process relay switching based on trend
of signal
Approvals IP 66 IP 65 (front) / IP 20
ATEX/FM/CSA
Applications RIT 261: deep well application Display, power supply, separate,, linearize, switch,
transform alternating pump control
Short Description Bargraph with 10% steps

36
Flow Computers.
RMS 621 RMC 621 Extension cards External display

Description

Energy Manager Flow and Energy Manager

Mathematical function Water/steam according Water/steam according to
to IAPWS-IF97 IAPWS-IF97
Natural Gas: NX 19,
SGERG 88, AGA 8
Real Gas: Soave-Redich-
Kwong (real gas)
Redich-Kwong (real gas)
Tables for gas
Tables for liquids
Ex-Certification None Optional Intrinsically safe inputs
and loop power supplies as
option for RMC 621
Custody Transfer None Planned
S-Dat Module None Yes
No. of inputs Basic device: 2x0/4-20 mA/pulse
2xPt100/500/1000 (max. 8 with extension cards) 1xloop power supply
2x0/4-20mA/PFM/pulse (max. 8 with extension 2 relay, SPST 5A/230V AC
cards) 2x digital passive
2x0/4-20 mA/pulse
output
No. of outputs Basic device: 2xPt100/500/1000-input
2x0/4-20mA pulse (max. with extension cards) 3/4-technique
3xloop power supply (max. 9 with extension cards) 2 relay, SPST 5A/230V AC
1 relay, SPST 5A/230V AC (max 7 with extension 2xdigital passive
cards) 2x0/4-20mA/pulse-
0 passive digital output (max 6 with extension cards) output
Interfaces RS232 in front Connection via RS485
RS485 at terminals
Second RS485 as option
Profibus interface
Possible branches and Saturated steam Food: CO2-Consumption Same mounting
applications measurement Solids: Heat recovering dimensions as DXF 351
Heat energy monitoring Energy: Natural gas
consumption, energy
management
Building Automation: Heat
metering for distribution
network
HVAC,
Chemical: Flue gas
cleaning, technical gas
filling
Benefits One unit for up to 3 One unit for up to 3 Easy wiring.
independent applications independent applications Power supply from basic
of steam and/or water. of steam and/or water unit.
3 applications in 1 device and/or gas and/or liquids. Operating as the internal
- save money for multiple Parameter storage on S- display.
measuring points. Dat-Module. Change of color when fail-
Modular extendable Online help for all ure; ease of identification.
number of I/O. operating positions.
Change of color
when failure; ease of
identification.
Online quick setup
- quick installation - save
money.

37
Digital Communications
Future Strategy Relies Heavily on
Network Technology
Endress+Hauser is first and foremost a manufacturer
of process instrumentation. They have built their
instruments to work in virtually any physical
environment, within virtually any control system
architecture that a customer may use. The
company, logically, has been and continues to be
an active supporter and participant of numerous
communication/network protocol standard
organizations. At one point, the company even had
developed its own communication protocol, but retired
it with the advent of more universal and what would
become more broadly adopted protocol standards, such
as HART, PROFIBUS, and Foundation Fieldbus. Today
E+H is following the strategy of open standards.
Concurrent with the developments in networking
standards and technology has been the development
of evermore intelligent sensors and transmitters.
The dramatic erosion in price for microprocessors
has enabled instrument manufacturers to embed
far greater capabilities and “intelligence” into their
instrumentation, leading towards the development
of instruments that have self-actualization. Self-
actualization is the next leap beyond just self-
validation to a concept whereby an instrument will
have the capability to know what its purpose is, where
it is located in a plant, work in conjunction with other
intelligent equipment to perform localized control,
self-diagnostics, calibration, validation, and even order
service in advance of an imminent failure. This will
revolutionize the monolithic control architecture of
today.
View the full ARC Strategies report by the ARC Advisory Group, visit : www.us.endress.com/OEM
38
Endress+Hauser clearly understands
the role that open standards play in the
markets it serves and has been an active
supporter and participant in the develop-
ment of such standards.
Coupling intelligent field instruments with standard
networking protocols creates opportunities, which
the company recognizes, for developing intelligent
systems that interact and provide localized control
at the device level, and not necessarily through a
larger control system. In so doing, a customer can
move to an architecture that addresses specific
localized control needs, for example, steam boiler
control, which will be easier to install, maintain,
and operate. Endress+Hauser has every intention
of providing industry with such complete packaged
solutions.
Leading this effort is E+H’s newest product center
(PC), created in late 1999, Process Solutions AG. This
PC has been given the charter to lead E+H’s efforts
to address the opportunities that will be created by
the concurrent advances taking place in networking
and sensor intelligence. These opportunities have
been broken up into three distinct categories:
Fieldbus Systems & Services (FSS), FieldCare &
ControlCare, and Engineering. Currently, Process
Solutions employs more than 70 professionals, half of
which are in R&D.
Successful Application Solutions
Equipment Manufacturer - Filling Machines

In the Manufacturing Industry

Dosimag Electromagnetic Flow Measurement System Offers Short Fill
Times, High Repeatability

Filling Machine manufacturer teams

with Endress+Hauser
This satisfied customer was among
the first companies in the world to
employ the use of flowmeters (mass and
electromagnetic) to monitor automated
filling technology. They dedicated
numerous studies and extensive research
in this direction, working closely with
Endress+Hauser to develop instruments
particularly effective in the applications
their customers were demanding.

This manufacturer got its start with the

manufacture of small, semiautomatic
machines for filling food products in
glass bottles. During the following years,
further technological development was
consistently pursued in order to meet
customers’ needs. In the 1970s a major
revolution in filling machine technology
for the chemical and food product
markets took place with the transition
from traditional glass packaging to
semirigid plastic packaging. An overhead view of a rotary filling head that utilizes 28
Dosimag A flowmeters.
The standards and regulations
that followed led to an increase in
prepackaged mass products in small
and medium containers. These events, coupled with increased requirements for safety, automation, and
monitoring, heightened interest among process manufacturers for accurate and cost-effective filling machine
technology.

The debut of Dosimag

The Dosimag A electromagnetic flow measurement system was released for sale in 1995 and this filling
machine manufacturer quickly became the first Dosimag customer. Endress+Hauser optimally adapted the
Dosimag A for their measurement task. The first tests confirmed expectations that it is an excellent, high
performance filling instrument.

Although the Dosimag A is specified for filling times of 1.5 s, the results achieved with filling times of 0.5 s
still lie within their machine’s accuracy specification.

39
Dosimag achieved high repeatability with very short filling times – the most critical parameter. The good
results prompted them to immediately place an order for 135 units. In less than two years the company placed
orders for more than 500 additional Dosimags.

Among the newest generation of filling machines at that location are systems that consist of a Dosimag A
electromagnetic flowmeter and a very fast dosing valve – an innovation. Depending on the version, the
machines are fitted with 18, 24, 28, or 32 filling heads.

They are a highly precise (±1.5 ml), rotating or in-line machines which, because of their flexibility, can be
adapted to the container to be filled. These machines offer highly sought after advantages including increased
machine speeds, faster change of different container sizes via a controller, reduced maintenance, and a sanitary
design.

Dosimag Advantages
The Dosimag measuring system offers an unobstructed cross section and no moving parts, while also ideally
fulfilling the filling machine manufacturer’s set requirements. Through elimination of a storage vessel, the
rinse procedure is greatly simplified. It is adequate to simply let a small amount of rinse liquid circulate in a
closed loop.

The following advantages result when employing the Endress+Hauser Dosimag in filling machine technology:

• Significant product savings from reduced overfills.

• Significant reduction of the cleaning times.
• Drastic saving of cleaners and, as a result, significant direct and indirect cost savings.

Programming of the filling machine controls is menu-guided on a single operating panel. Complete system
configuration is carried out using the PLC, allowing the operator to easily set the:

• Container size change

• Tolerances
• Alarm limit values
• Monitoring of filling heads.

The filling machines from our customer, with either electromagnetic or Coriolis mass flowmeters, have a
wide range of application possibilities in various industries including perfume and cosmetics, pharmaceuticals,
household products, food, beverage, and dairy.

Endress+Hauser Dosimass
coriolis mass flowmeter

An example of two Dosimag A units prior to

installation, fitted with plastic process connections.

40
Food & Beverage Industry - Packaging Machinery

In the Food & Beverage Industry

Dosimag’s Exceptional Repeatability & Cost Effectiveness Impress User

When our customer, a leading manufacturer of food and beverage products, was ready to work with a Georgia
packaging machinery company, Endress+Hauser Dosimags were specified up front.

The local Endress+Hauser representative recalls that the original

equipment manufacturer (OEM) was familiar with Endress+Hauser flow
products, but they had not previously used Dosimag.

“Through testing they were quite aware of the accuracy offered by the
Promass mass flowmeter, as well as the batching feature of the Promag,”
notes the representative. “They hadn’t used Dosimag for any of the in-
line and rotary filling equipment they manufacture.”

Yet the customer, producer and bottler of a wide range of popular food
and beverage items, knew Dosimag would best meet their needs.

Prior to specifying the Endress+Hauser meter, the customer had

completed extensive testing of the Dosimag against a major competitor’s Dosimag‘s compact size, exceptional
flowmeter. Dosimag emerged as the clear winner. As a result, the repeatability, and the reliability
customer decided to modify their weight filler to a volumetric filler using achieved from a meter with no moving
30 Dosimags. parts led the customer to specify its
use on new packaging machinery.
Popular features that sold the customer on Dosimag included its compact
size, exceptional repeatability, and the reliability achieved from a meter
with no moving parts. Dosimag is designed to provide quick and accurate
flow measurement in batching and filling plants. When linked to a plant
control system, Dosimag can carry out an automatic change in fill volume
without interrupting the production flow.

The switch to Dosimag was part of a major plant upgrade for the customer. The bottling plant needed to invest
in upgrades of meters and on-line equipment – a one-off expenditure of about $400,000. This still resulted in
overall savings of nearly $500,000 and even greater savings are expected over the long-term.

41
Beverage Industry - Filling Machines

In the Food & Beverage Industry

Dosimag’s Exceptional Repeatability & Cost Effectiveness Impress User
The Situation
In 1996 a customer asked a large manufacturer of beverage filling equipment for the soft drink and brewing
industries, to develop a customized filling machine. Response time was critical to the customer, and it was
difficult to find a flowmeter that could meet the parameters.

Their new machine was virtually complete, but it would not fill the containers within the
specified volume. The problem was that the electromagnetic flowmeter they were using did not
have the capability to provide the necessary repeatability that is critical to high speed fillers.

Officials of the manufacturer were aware of the reliability and accuracy associated with
instrumentation from Endress+Hauser. For more than 10 years they had used E+H products
in the manufacture of beverage packaging equipment, such as custom blending machines and
fillers for customers like soft drink manufacturers, and large breweries.

The Suggestion
Dave Schwanz, an Endress+Hauser sales representative with MAC Systems, suggested that this manufacturer
give the Dosimag electromagnetic flowmeter a trial run. A test and evaluation unit meeting the exact size
specifications the manufacturer required was immediately shipped from Greenwood, Indiana to their plant.

“We tested several electromagnetic flowmeters before making our decision, and the Dosimag simply
outperformed the others for high speed filling,” explains a research and development engineer.

The Dosimag was easy to install and, from both mechanical and electrical standpoints, it fit the application
perfectly. The results achieved with the Dosimag were extremely repeatable.

“The Dosimag responded well and was very repeatable throughout the testing,” relates the engineer. “With our
equipment we could not measure any difference in weight or volume from fill to fill.”

The Solution
Following the success with the test and evaluation unit, the manufacturer immediately placed an order for
another 19 Dosimags to complete the job. At their request E+H sent separate electrical connectors for the
meters ahead of time so the machine’s wiring could be completed in advance of the flowmeters’ arrival.

Once the 20 Dosimags were installed the machinery met all specifications and was promptly shipped to their
customer. The manufacturer anticipates the potential for strong growth, due to automation in the beverage

In today’s cost-conscious environment,

quality filling equipment must
feature accurate metering to avoid
the expense of overfills. The filling
equipment manufacturer ensures
quality equipment with the installation
of Endress+Hauser’s Dosimag – the
standard meter for all their meter-
based machinery.

42
industry, and their customers’ demands for more reliable and accurate fillers. With the improved performance
their machine was able to deliver by utilizing Dosimags as the metering instrument, the manufacturer
anticipates increased orders for similar fillers in the future.

They have been aware of Endress+Hauser level and pressure products, primarily capacitance systems, sanitary
probes, and the Prolevel. Now they are fully aware of the capabilities of flow measuring products from
Endress+Hauser. Endress+Hauser had the right product for the customer’s needs and delivered it in the time-
frame that met the customer’s requirements.

Manufacturer Follows Parent Company’s Lead

The manufacturer’s parent company has also realized the benefits of the Dosimag, as it has become the
standard for their meter-based machines, as well. They have already produced dozens of high-speed fillers
using the Dosimag for the beverage industry.

As one of the largest suppliers of filling machines in the world, they continue to tout the advantages of using a
meter-based system over the older, level-based technologies. Through that process they demonstrate dramatic
efficiency improvements to their customers, and incredible product savings. On one machine with a capacity of
30,000 bottles per hour, the precise metering offered by the Dosimag was able to produce an annual savings of
275,000 liters.

43
Equipment Manufacturer - Net Weight Filling System

In the Equipment Industry

Promass Provides Stability & Repeatability During Fill Cycles
The Situation
Seven years ago a customer embarked on an effort to produce what would become the world’s first complete
filler family for net weight filling – a system that would employ Coriolis mass flow measuring technology.

The Buffalo, New York, manufacturer wanted a system that would distinguish them from the competition.
They wanted a system that could span a large variation in fill size and liquid characteristics; a system with
faster response time than weigh-cell based systems.

In 1996 our sales representative with Afta Controls met with the customer’s ownership and engineering
management team. Through a series of discussions, meetings and audits, our representative learned specifics
about a new system and customer officials gained familiarity with the Promass line of mass flowmeters from
Endress+Hauser.

“Our customers were asking for a filling machine which reduced overfills and provided the ability to meet
tighter regulatory standards and satisfy growing statistical process control expectations,” explains our
customer’s CEO.

To meet these demands our customer officials looked at their technological options. Until the birth of the
new system there were two systems for producing net weight fills: weigh-cell based units designed for
pharmaceutical applications, and scale based net weight rotary fillers. Both lacked the flexibility and versatility
for broad market acceptance.

The new system features flowmeters employing Coriolis technology, meters that can measure the mass flow of
virtually any liquid. Before selecting the Endress+Hauser line of Promass flowmeters, the customer performed
extensive testing on instruments from three major manufacturers.

The Solution
“The customer petitioned for a 1 inch Promass to test,” recalls the representative. “They were both pleased and
excited about the results and subsequently tested a ½” and 3/8” meter – both of which they later purchased.”

Endress+Hauser representatives continued to work closely with the customer’s engineering team to develop the
baseline of data needed to confirm that the Promass was the instrument that would allow them to launch the
new system. The stability and repeatability of the Promass allows the customer
to manufacture and market it to control fill weight without worrying about
problems caused by product changes during fill cycles. With Promass they do not
have to sacrifice the flexibility of the machine to run virtually any type of liquid
and handle a vast range of containers and dose sizes.

The Endress+Hauser Promass meters proved to be capable of meeting or

Promass is installed in the
customer‘s automated filling
system. The Endress+Hauser
mass flowmeter was selected
following extensive testing by the
customer on instruments from
three major manufacturers.
exceeding this customer’s standards for accuracy and stability of results. Data
from their testing results found that Promass can track true liquid density. This
allows the filler to produce net weight fills in real time, regardless of changes
in product temperature, viscosity, pressure or specific gravity. In addition, the
Promass meets 3-A sanitary standards and FDA specifications.
The technological partnership that has developed between this customer and
Endress+Hauser will better enable both companies to broaden their customer base
as industries demand high quality products from providers.

44
Food Industry - Dairy

In the Dairy
Promag Electromagnetic Flowmeter Controls Pasteurizer Flow

Magnetic flowmeters often play a critical role in controlling the flow rate on dairy pasteurizers. When installed in
conjunction with a centrifugal pump and control valve, the meters effectively monitor and control the flow rate
through the holding tube. Once the FDA inspects for proper flow rate to assure pasteurization time, the meter is
sealed prior to operation in accordance with the Pasteurized Milk Ordinance (PMO).

Process Overview
At a temperature of 40°F the cold, raw milk is drawn from a balance tank. It enters a regenerator section of the
pasteurizer where – on the opposite side of thin, stainless steel plates – hot, pasteurized milk flows in a counter
current direction. Heat from the pasteurized product warms the raw milk to approximately 160°F. While still
under suction, the raw milk passes through a centrifugal pump and magnetic flowmeter, arriving under positive
pressure through the rest of the High Temperature Short Time (HTST) system.

As it is forced through the plate exchanger hot water on opposite sides of the plates heats the raw milk to a
temperature in excess of 187°F. While at this pasteurization temperature and still under pressure, the milk flows
through the holding tube where it remains for at least 16 seconds. Measurements from the electromagnetic
flowmeter govern the maximum velocity. After passing an indicating thermometer’s temperature sensor and a
recorder-controller at the end of the holding tube, the milk moves into the Flow Diversion Device (FDD).

The FDD assumes a forward-flow position if the milk passes the recorder-controller at the preset cut-in
temperature. The FDD remains in normal position (in diverted flow) if the milk has not achieved the preset cut-in
temperature. The improperly heated milk flows through the diverted flow line of the FDD back to the raw milk
balance tank. Properly heated milk flows through the forward flow section of the FDD. The product then moves

45
to the pasteurized milk regenerator section where it gives off heat to the raw product and in turn is cooled to
approximately 52°F.

The warm milk passes through the cooling section where it is cooled to 40°F or below by coolant on opposite
sides of the thin, stainless steel plates. Finally, it moves onto the storage tank filler for packaging or further
processing.

The role of instrumentation from Endress+Hauser

In place of the positive displacement timing pump the Promag 53H and associated control valve monitors and
controls the flow rate through the holding tube. In comparison to a positive displacement pump, the Promag
53H, working with the centrifugal pump, offers a maintenance-free system with minimal up-front costs. The
largest advantage of this system is that it can be completely cleaned-in-place while the timing pump must be
disassembled and cleaned-out-of-place.

Specifically designed to meet the sanitary requirements within the dairy industry, the Promag 53H comes with
a standard locking screw that allows the inspector to seal the instrument after inspection. The Promag 53H was
also engineered to meet the intent of the PMO and its requirements for magnetic flowmeters.

Unmatched in terms of sanitary design, the Promag 53H not only meets 3-A, FDA, and EHEDG guidelines,
but is also designed with the same diameter as typical food tubing. This ensures the product does not develop
bacterial growth within the instrument.

Designed to handle difficult CIP cycles, the transfer molded PFA liner on the Promag 53H is capable of handling
cleaning temperatures of up to 300°F. It is also available with a remote transmitter option for optimum
functionality and cleanability in wash down conditions.

Other potential food and beverage applications

The Promag 53H is also suitable for many other applications within the dairy plant. It has been used to control
and measure the following processes:
• Milk Reception
• Fat Standardization
• CIP Control
• Flow Control to Packaging

The sanitary design and functionality of the Promag 53H renders it unmatched in today’s market for supporting
Critical Control Points (CCP) within the dairy industry.

Promag H meets the strict sanitary require-

ments of the food industry. It is the only
electromagnetic flowmeter certified by 3-A
and tested by EHEDG.

46
Food and Beverage Industry

How does a CIP System Work?

CIP — Clean in Place is Used in Many Operations

There are many different configurations and designs. But a general principle applies – cleaning is done without
removing process components through flushing the system with cleaning agents. The following terms are used
to define the degree of cleanliness:

Physical cleanliness: removal of all visible dirt from the surface;

Chemical cleanliness: removal not only of all visible dirt, but also of microscopic residues which can be
detected by taste or smell but are not visible to the naked eye;
Bacteriological cleanliness: attained by disinfecting;
Sterile cleanliness: destruction of all microorganisms.

It is important to note that equipment can be bacteriologically clean without necessarily being physically or
chemically clean. A typical CIP run consists of a Recovery of product residues by scraping, drainage and
expulsion with water or compressed air, Prerinsing with water to remove loose dirt, Cleaning with detergent,
Rinsing with clean water, Disinfecting by heating (steam) or with chemical agents if this step is included the
cycle ends with a final rinse, if the water quality is good.

Each stage required a certain length of time to achieve an acceptable result. Four components (Time,
Temperature, Concentration and Velocity) determine the effectiveness of the CIP and is optimized for each
application.

An example of CIP systems are single use, 1, 2, 3 or 4 tank system. The number of tanks describe how CIP
media is recovered or what detergents are used. Above is an example of a 3 tank system. CIP systems are
designed for central or de-centralized systems. Central systems are used for smaller plants where it is practical
to use one centrally located CIP and a de-centralized system is often used for larger facilities. As a general rule,
separate CIP systems are used for raw and pasteurized product. HTST pasteurizers and UHT systems have

47
dedicated CIP systems. There is also a differentation between line circuits and tank circuits. Tanks are
cleaned using bursts of flow through a spray ball or a rotary nozzle. Cold processes commonly only use a
caustic detergent (typically sodium hydroxide) while hot services may use caustic and acid (typically Nitric or
Phosphoric acid) to remove burnt or caramelized deposits. A CIP program for a “hot components” circuit can
consist of the following stages:
1. Rinsing with warm water for about 10 minutes.
2. Circulation of an alkaline detergent solution (0.5 to 1.5%) for about 30 minutes at 170 °F.
3. Rinsing out alkaline detergent with warm water for about 5 minutes.
4. Circulation of (nitric) acid solution (0.5 to 1.0%) for about 20 minutes at 160 °F.
5. Post-rinsing with cold water.
6. Gradual cooling with cold water for about 8 minutes.

The circuit is usually disinfected in the morning, before production starts. This is typically done by circulating
hot water at 195 to 205 °F for 10 to 15 minutes after the returning temperature is at least 185 °F.

To control the process, flowmeters are used to ensure that the correct flushing action takes place. Note that flow
velocity of 5 to 10 ft/sec is common during CIP. This is sometimes overlooked when sizing flowmeters since the
flow rate of the process media is usually much lower. Temperature of CIP is closely monitored, if temperature is
too low the effectiveness of the cleaning is compromised. As a rule of thumb, cleaning with alkaline detergent
should be done at the same temperature, as the product has been exposed to, but at least 160 °F.

Concentration of the CIP detergent is monitored by conductivity measurement. Commonly two points are
monitored, the concentrations in the CIP tank and on the CIP return line. The transmitter on the CIP return
line controls the CIP diverter valve. Depending on the system the diverter valve returns the CIP fluid to the
CIP tank for reuse or dumps it to drain. The response time and performance of the conductivity transmitter is
important. A slow response often results in unnecessary waste of CIP chemical to drain, resulting in higher cost
for replacement chemicals, heating of more media and additional cost for water treatment.

What can Endress+Hauser supply for CIP systems?

Balance tank
• Deltapilot S DB 50S – ideal because of small range capability and temperature compensation. Balance tanks
see rapid level and temperature changes.
• Liquiphant M – High/low level alarm – even though the DB 50S is a very good device, the balance tank
may overlow or run empty.
• Capacitance (or Levelflex M with sanitary fitting) – an alternative to Deltapilot S for level measurement.

CIP Chemical storage tanks

• Level measurement with Cerabar M PMC 45, Deltapilot S DB 50S. Alternatives are Ultrasonic FMU 40 but
look out for foam.
• Conductivity transmitter CLS 52 with CLM 253 or CLD 132 for concentration measurement of CIP
solutions. Some users prefer pH (accuracy is a little better but additional labor to calibrate and maintain is
hard to justify).
• Liquiphant M for over-spill protection.

Chemical (CIP) header tanks

(Small tanks with about 100 to 200 gallon capacity)
• Capacitance DC 12 + FEC 12 or Levelflex M.
Ultrasonic may work but foam is often present.
• Conductivity transmitter for CIP concentration (not always used here).

Sanitizer solution tank

• Sometimes pH measurement is used for sanitizer concentration.

CIP flow
• Promag 50 H. Competition often propose sanitary Vortex. Promag offers several benefits: True full bore
design, no pressure drop and much better turndown. Vortex cannot measure at low flow (cuts off at about
13 gallons/minute for a 2” line). Vortex meters are often sensitive to pipe vibrations – most are used. Price

48
 is comparable. Keep in mind that CIP rinse water for pharmaceutical applications may be ultrapure or even
WFI (water for injection) with conductivity too low for magnetic flowmeters. We have on several occasions
used Promass for these applications, for example, Promass 40E, 80E or 80F.
• Conductivity transmitter for CIP return line – CLD 132 or CLS 52 with CLM 253. Used to control
diverter valve. Many CIP systems are timing based, this can result in alot of waste. A system controlled by
conductivity is far more efficient.
• Liquiphant M FTL 50 H for pump dry-run protection. Primarily applicable if PD pumps are used.
Centrifugal pumps are less prone to damage.
• Temperature – applications can be found at several locations to ensure that correct cleaning temperature is
maintained.

49
Pharmaceutical Industry - Purified Water

In the Pharmaceutical Industry

Cerabar M Pressure Transmitters Effectively Monitor Reverse
Osmosis Unit

Purified water is among the most heavily treated utilities used by the pharmaceutical industry. All pharmaceutical
production requires the use of large volumes of water. For smooth operation at any pharmaceutical facility,
production and validation of these waters is critical. The FDA has scrutinized the process in recent years, with
volumes of information added to the general chapters in the latest United States Pharmacopeia 24. One of the
most important components is the reverse osmosis unit.

Process Overview
Reverse osmosis units employ a semipermeable membrane and a substantial pressure differential that drives water
through the membrane to achieve chemical, microbial, and endotoxin reduction. The most commonly used
membranes today are the spiral-wound, thin film variety. The membranes are designed using a cross-flow design
to minimize fouling. A two-pass system can remove from 95 to 99% of ionizable salts, while also greatly reducing
bacteria levels.

Remember, an RO unit is not designed to sanitize the water, but should be viewed as a biological reduction. The
reliable operation of an RO unit depends heavily on the pretreatment stages. Care must be taken to correctly
select the pretreatment components and ensure proper operation.

For effective operation of RO units, attention must be given to:

• Seal integrity
• Membrane integrity
• Fouling of the membrane
• Sanitation of RO unit

50
To detect any of the above conditions, monitoring instrumentation must be employed.

Today, the most common approach is to monitor the differential pressure between the inlet and the outlet of
the RO train. When the membrane becomes fouled or a seal fails, the differential pressure transmitter alerts the
control system. Conductivity and TOC levels are also monitored. The importance of controlling pH levels, at the
inlet of both first and second stages, is becoming increasingly recognized.

The role of instrumentation from Endress+Hauser

An alternative approach to a single differential pressure transmitter uses two pressure transmitters to measure
the inlet and outlet pressures independently. The two values are then transmitted back to the PLC, DCS, or
math module via the 4-20 mA current signal. The outlet pressure is subtracted from the inlet pressure to obtain
an electronic differential pressure. A side benefit is the inlet pressure reading is also obtained without additional
hardware. The feed water inlet pressure significantly impacts the performance of the RO unit, and must be
controlled at an optimum level.

Problems with seal and membrane integrity are quickly detected by a decreasing DP. Similarly, increases in DP
will indicate membrane fouling.

Endress+Hauser’s pressure transmitter, the Cerabar M, was developed with just this type of application in
mind. Cerabar M has a unique 99.9% pure ceramic sensor that has no fill fluid; and it is chemically resistant
to CIP chemicals and sanitizing agents. Because there are no fill solution or long capillary tubes with remote
seals, drift (caused by changing temperature effects on conventional DP transmitter designs) is eliminated.
The Cerabar M transmitter is designed to meet the highest sanitary standards. It is certified by the European
Hygiene Equipment Design Group (EHEDG), and meets 3-A sanitary requirements.

Benefits of the Cerabar M

• Unaffected by rapidly changing temperatures
• Harsh chemicals, pressure, and vacuum shocks will not damage ceramic sensor
• Flush process connection ensures easy cleaning and sanitation
• All stainless steel housing meets pharmaceutical requirements
• Smart electronics ensure reliable operation and easy setup
• Monitors line pressure in addition to DP value

Other potential pharmaceutical applications

The Cerabar M is just one member of the Endress+Hauser line of pressure and DP transmitters. We have the
right transmitter for every application – from simple monitoring of compressed air, to the most sophisticated
application.
• Fermenter tank level measurement, using electronic DP
• WFI tank level measurement, using hydrostatic pressure
• Multimedia filter monitoring, using electronic DP
• Line pressure of liquid, gases, and steam

Since the 99.9% pure ceramic

sensor requires no fill fluid,
drift problems – inherent to
conventional DP transmitters
– are eliminated.

51
Pharmaceutical Industry - Purified Water

In the Pharmaceutical Industry

Conductivity System Ensures Accurate Monitoring in Accordance
with Regulations

Purified water is among the most heavily treated utilities used by the pharmaceutical industry. All
pharmaceutical production requires the use of large volumes of water. For smooth operation at any
pharmaceutical facility, production and validation of these waters is critical. The FDA has scrutinized the
process in recent years, with volumes of information added to the general chapters in the latest United States
Pharmacopeia 24. A significant change made to USP 23, and adopted in the latest USP 24, concerns monitoring
of purified water and water for injection. On-line conductivity measurements must now be performed in a
specific manner.

Process Overview
Water arrives at a storage tank following the water pre-treatment and reverse osmosis stages. At this point
the water is considered purified water (PW) or USP water. Ozone is normally added to control microorganism
proliferation. The water is continuously re-circulated in a sterile system. It may pass through an ultraviolet (UV)
unit to remove ozone prior to the point of usage (POU). This water is also the feed water for the stills to produce
water for injection (WFI).

The USP 24 general chapters section 645, stage 1, describes the manner in which conductivity must be
measured:
• Two current outputs must be provided by the analysis instrument – one for raw specific conductivity, and a
second for temperature
• The analyzer (meter) must have a minimum accuracy of 0.1 µS/cm
• The sensor (cell) must have a verifiable cell constant of ± 2%

52
To meet the requirements of stage 1, the conductivity values must be below the limits reflected in Table 1. The
process temperature reading is rounded down to the next closest temperature on the table. If the conductivity is
below the corresponding value, the water has passed.

Action levels are normally set to ensure the water conductivity never reaches the limits in the table below.

Temperature °C Conductivity Temperature °C Conductivity

(uncompensated) (uncompensated)
0 0.6 55 2.1
5 0.8 60 2.2
15 1.0 65 2.4
20 1.1 70 2.5
25 1.3 75 2.7
30 1.4 80 2.7
35 1.5 85 2.7
40 1.7 90 2.7
45 1.8 95 2.9
50 1.9 100 3.1

The role of instrumentation from Endress+Hauser

With Endress+Hauser’s conductivity system, users are assured of accurately monitoring water in accordance
with USP 24. With the USP 24 table imbedded internally, the Liquisys analyzer offers as many as four internal
relays for alarming purposes. This eliminates the need for the user to program the table into a separate device
since all alarms are generated within the analyzer.

The alarms are set in terms of percentage of the maximum allowable conductivity value for a corresponding
temperature. Two current outputs for temperature and conductivity are also provided.

The Liquisys analyzer is available in two housing configurations – NEMA 4X field enclosure and a compact ¼
DIN panel mount. Remote configuration via HART® and Profibus are also available.

Calibrated with ASTM-produced standards, the precision conductivity sensors are delivered with a certificate
and a precision cell constant. The CLS 15 sensor is made of 316L stainless steel to meet the stringent demands
of the pharmaceutical industry. The sensor is polished to 240 grit (16 Ra), easy to clean, and can be sterilized up
to a maximum of 302°F (150°C). The sensor is also available in 1.5” or 2” Tri-clamp process connections.

Since USP 24 requires that sensors have a verifiable cell constant, Endress+Hauser also offers a unique on-site
verification of cell constant, without requiring removal of the sensor from the sterile line.

The locations for the conductivity sensors are:

• After the RO unit
• The return circulation to the USP storage tank
• After the still
• The return circulation to the WFI storage tank
• Strategic locations within the distribution system

The CLS 15 precision con-

ductivity sensor is positioned
after the reverse osmosis unit,
stage 1.

53
Pharmaceutical Industry - Purified Water

In the Pharmaceutical Industry

Turbidity Sensor Performs Effectively in Multimedia Filter Backwash,
Ripening Control

Purified water is among the most heavily treated utilities used by the pharmaceutical industry. All
pharmaceutical production requires the use of large volumes of water. For smooth operation of any
pharmaceutical facility, production and validation of these waters is critical. The FDA has scrutinized the
process in recent years, with volumes of information added to the general chapters in the latest United States
Pharmacopeia 24.

Process Overview
While the multimedia filter primarily removes suspended solids from the water, the filter also plays a critical
role in the pretreatment process. A well-designed multimedia filter uses gravel, manganese green sand, and
anthracite, enabling these units to remove suspended solids as small as 5 to 10 microns. The manganese also
helps remove iron.

When loaded with suspended solids, multimedia filters must go through a backwash process. This is normally
accomplished today by either using a fixed time interval, or by monitoring the differential pressure between the
inlet and outlet to trigger the backwash cycle.

In the second scenario, the backwash cycle starts when the differential exceeds 6-9 psi, depending on the unit.
This approach accomplishes the task, but it does not monitor the unit’s real “filtering” performance. Channeling
of filter media often occurs when filter media is sized incorrectly, or flow rates are not controlled.

An alternative approach monitors the outlet with a turbidity analyzer. When the multimedia filter is working
optimally, the turbidity readings will be low, typically below 0.5 FNU (Formazine Nephelometric Units). When
the media becomes saturated or channeling occurs, the turbidity reading increases rapidly. Backwash can be
optimally controlled with the turbidity reading.

54
Traditionally, turbidity sensors have been placed in low pressure sample lines. An air degassing chamber is
needed to compensate for air bubbles that cause significant errors when measuring in low turbidity ranges. Low
pressure sample lines also tend to trap suspended solids, necessitating routine cleaning.

The role of instrumentation from Endress+Hauser

The CUS 31 sensor from Endress+Hauser is designed for installation in a pressurized sample line, eliminating
the challenges associated with degassing. Scratch-resistant sapphire lenses, and an integral wiper that removes
light coatings, significantly reduce maintenance requirements.

The CUS 31 turbidity sensor undergoes a high quality, three-point factory calibration, using ultrapure water
and formazine. The sensor compensates for aging effects on electronic components, eliminating the need for
any future re-calibration! The wiper keeps the lenses clean, practically eliminating maintenance requirements.

The turbidity sensor and chamber should be positioned on the sample line so that the multimedia outlet is
continuously monitored, both during the ripening phase, as well as normal run conditions. The sample line’s
outlet must provide sufficient back pressure to eliminate degassing, while also running to waste.

After the backwash process, the multimedia filter must “ripen.” During this time the filter bed is not performing
optimally and will not remove suspended solids correctly. While the filter is ripening, the outlet must run
to drain. By monitoring the turbidity of the outlet during this phase, the ripening time can be reduced to an
optimum time, while ensuring that no suspended solids are released downstream.

The CUS 31 turbidity sensor connects to the Liquisys CUM 223/253 analyzer, available in both field and panel-
mount housing configurations. The analyzer features a two-line display for easy menu operation, as well as dual
current outputs for turbidity and temperature retransmission of readings. Integrated controllers can be used to
activate up to four relay contacts. HART® and Profibus® interfaces are also available.

CUS 31 sensor benefits

• Wide measuring range with excellent resolution
• No drift, factory calibration eliminates the need for recalibration
• Integrated wiper keeps lenses free from biological coatings
• Pressurized sample chamber eliminates air bubble problems
• Sample system eliminates need to sanitize the turbidity system

Other potential pharmaceutical applications

The Liquisys turbidity analyzer and the family of sensors cover a very wide range of applications, including:
• Control and monitoring of ultrapure water
• Breakthrough detection in filtering systems
• Monitoring of chilled water to detect product contamination
• Suspended solids monitoring in wastewater systems
• Concentration monitoring in activated sludge systems

Because it compensates for aging

effects on electronic components,
the CUS 31 turbidity sensor never
requires recalibration.

55
Pharmaceutical Industry - Fermentation

In the Pharmaceutical Industry

Steam Sterilizable pH Electrodes Reduce Operating Costs

The field of Biotechnology has become an exact science that is broadly used to produce many products in the
fields of Genetics, Microbiology, Immunology, Agriculture, Plant Science, Medicine and Environment. The
fermentation process is used in many different applications – from ethanol, to growing tissue cell cultures for
vaccines. Of critical importance in most fermentation processes is the reliable monitoring and control of the pH
value.

Process Overview
Large and small fermenters are equipped with two to three pH electrodes. Hydrogen ion sensitive pH
electrodes, whether constructed with plastic, stainless steel, or glass outer shafts, all have a glass membrane
in contact with the process. The glass membrane is specially formulated to be hydrogen ion sensitive. The
membrane is attached to a glass shaft of a different formulation. Care must be taken to ensure that, under the
rigorous conditions seen in fermenters, these different materials work well together.

At the end of a run, the fermenter vessel will be cleansed with chemicals and sterilized with steam. Steam
sterilization normally lasts for an hour and is controlled at 250°F. During sterilization, the electrode
components will expand, causing stress to occur between the different materials of construction. The rapid
change in temperature, be it from cold to hot or vice versa, is by itself often the cause of pH electrode failure.

The internal electrolyte in many electrodes will expand and cause an increase of pressure, resulting in glass
bulb breakage. Steam is produced from low conductivity water, which is so “hungry” for ions that it tends to
leach free ions from the glass membrane, resulting in reduced performance of many pH electrodes. Most pH
electrodes will survive 6 to 10 steam sterilizations before failing.

56
The role of instrumentation from Endress+Hauser
Under process conditions the rugged Orbisint CPS 11 electrode withstood 30 steam sterilization cycles (50
under reference conditions), significantly extending the life expectancy of pH sensors in such challenging
applications. The Orbisint CPS 11 offers a host of features not found in other pH electrodes:
• Every batch of glass is matched to ensure expansion coefficients are the same
• Special glass formulations and pressure absorption systems to protect against rapid changes in temperature
• PTFE junction is resistant against fouling and prevents biomass from penetrating the reference solution
• Secondary containment area for the reference system, that offers protection from contamination
• The gel electrolyte is polymerized in the electrode during production, eliminating “poisoning pathways”
that exist in many electrodes
• The single junction design of the CPS 11 eliminates errors caused by changing transfer potentials that
develop across multiple junctions in other designs

In addition, a temperature sensor, located right in the tip of the CPS 11, can be used to monitor steam steriliza-
tion temperatures and achieve improved accuracy during buffering.

All Endress+Hauser electrodes are equipped with a new quick cable connector, eliminating the need to replace
the cable with each electrode failure. The TOP 68 connector is completely waterproof, exceeding NEMA 6P
and IP 68 ratings.

In a cost of ownership example, based on the number of electrodes required for 100 sterilization cycles, a signi-
ficant savings can be realized.
Cost of Ownership For 100 Sterilizations Customer:
E+H Sensor with Competitor with Competitor with
TOP 68 Fixed Cable Quick Connector
Number of Fermentors: 1

Replacement Sensor Costs:

Total Sensor Replaced/100 Sterilizations 4 10 10
Replacement Sensor Cost Each $194 $150 $190
Total Sensor Replacement Cost/Fermentor $776 $1,500 $1,900
Total Sensor Replacement Costs All Fermentors $776 $1,500 $1,900

Associated Replacement Labor Costs:

Burdened Labor Rate $80 $80 $80
Labor Time Each Replacement (minutes) 10 30 10
Labor Time Total (hours) 0.67 5.00 1.67
Total Labor Costs/Fermentor $53.33 $400 $133.33
Total Labor Costs/All Fermentors $53.33 $400 $133.33

Total Replacement Costs:

Total Replacement Cost/Fermentor $829.33 $1,900 $2,033.33
Total Replacement Cost/All Fermentors $829.33 $1,900 $2,033.33

Note: Prices are for reference only.

As the world’s largest producer of pH electrodes, Endress+Hauser ensures constant product quality, with unique
production and test tools.
• Automated glass bulb blowing
• Automatic bonding of silver to platinum internal electrode leads
• Automated final inspection with slope and zero point measurement of each electrode
• Test certificate, warranty supplied with each electrode

57
Pharmaceutical Industry - Fermentation

In the Pharmaceutical Industry

Retractable pH Electrode Holder Ensures that Sanitary Conditions are
Maintained During Fermentation Process

The field of Biotechnology has become an exact science. Biotechnology is broadly used to produce many
products in the fields of Genetics, Microbiology, Immunology, Agriculture, Plant Science, Medicine and
Environment.

The fermentation process is used in many different applications – from ethanol to growing tissue cell cultures
for vaccines. Modern facilities use aseptic techniques to minimize the risk of contamination that could
adversely effect yields, product quality, taste, texture, aroma and appearance. The value of the product and the
risk of contamination will determine the degree to which precautions should be taken.

Fermentation processes using yeast and bacteria are sometimes so hardy that moderate amounts of
contamination from outside the fermenter would not effect their domination. The high-risk applications are
found in cell cultures and in microbial fermentation applications.

Biochemical engineers are faced with many challenges when it comes to designing and building effective
fermentation processes. One of the most important areas relates to the prevention of contamination.

Process Overview
One of the most critical control parameters is the pH value in the fermenter during the growth phase.
Successful growth of organisms or cells require pH values to remain within a specified window; tolerances can
be as small as 0.1 pH units. Reagents, buffers, and CO2 are normally used to control the pH value. However,
effective control of pH requires repeatable measurement as a prerequisite.

58
Experienced users know that the ultimate process pH electrode has not yet been developed. Electrodes are
by nature prone to problems of drift, erroneous readings, slow response, and worse, no response at all. The
reasons for these failures are sometimes complex. Following is a brief list describing symptoms and causes of pH
measurement problems:
1. If the electrode is left to dry out, the sensitive glass bulb becomes dehydrated, the electrolyte crystallizes
blocking the junction. This happens when operators forget to remove electrode housings from the port
while the fermenter is off-line.
2. If the electrode junction becomes coated with proteins or fouled, an offset will be evident and
measurement becomes sluggish. Insufficient cleaning of the electrode leads to this result.
3. If the glass is damaged by abrasion the impedance drops, resulting in a decreased milli volt output.
4. If the silver chloride reference system is chemically reduced an offset will be evident – leading to erroneous
readings.
5. If the electrolyte becomes contaminated with biomass, causing an internal change in electrolyte
concentration – erroneous readings will result. This is often caused when a vacuum is created within
the reference system, as the rear of the pH electrode cools down faster than the process does after steam
sterilization.
6. If small cracks appear in the glass bulb, an electrical short circuit will occur rendering the electrode
useless. This is caused by the rapid changes in temperature during steam sterilization. Since the different
glass types in most pH electrodes have different expansion coefficients, these rapid temperature changes
create stress points that lead to hairline cracks.

The role of instrumentation from Endress+Hauser

As an alternative approach to using stationary pH electrodes, retractable electrode holders offer greater
flexibility and convenience. On the market for some time, retractable pH electrode holders can be automatically
removed from the process.

Retractable holders can be retracted from the fermenter whenever required – even if the fermenter is still on-
line. The natural concern here is the ability to reinsert the electrode into the vessel without introducing any
contamination into the fermenter.

The sanitary retractable holder from Endress+Hauser is the first to offer assurance of a sterile operation. The
wider-body process connection of the CPA 465 holder eliminates the need to use o-rings. With the retractable
electrode holder, steam and cleaning agents reach all the way down to the back of the primary form seal.
Cracks and crevices have also been eliminated.

The holder’s stroke is designed so the process wetted moving parts are in complete contact with the steam
when the holder is in the retracted position. To facilitate effective cleaning and sterilization during tank
washing, the process wetted side of the holder remains flush.

The sterilization chamber inlet is positioned for direct assault on the area behind the primary form seal, where
the electrode tip is located. The cleaning agent or steam will move upwards in a swirling action to exit at
the outlet (Z-type cleaning). The chamber is mechanically separated from the pneumatic cylinder by an open
lantern design, minimizing heat transfer during steam sterilization cycles.

The CPA 465 electrode holder has been tested at the TNO Laboratories in the Netherlands, in accordance
with the European Hygienic Equipment Design Group (EHEDG) procedure for evaluation of steam sterilizable
equipment. The holder passed in three separate tests.

The CPA 465 holder uses specially designed form

seals and no o-rings, making it easy to clean via SIP
and CIP procedures

59
Pharmaceutical Industry - Purified Water

In the Pharmaceutical Industry

Transit-Time Ultrasonic Flowmeter Offers Advantages in Controlling
Flow Rate of Purified Water Loop

For pharmaceutical purposes, water is highly regulated. U.S. Pharmacopeia (USP) and National Formulary (NF)
have a complete section regarding water standards in their latest standard USP 24 and NF 19. USP and the NF
standards are recognized by the official compendia in the Federal Food, Drug and Cosmetic Act. These statutes
usually empower the government agency to enforce the law.

Process Overview
USP 24 regulates the water for pharmaceutical purposes in the section “General Information / [1231] Water for
Pharmaceutical Purposes.”

The distribution configuration should allow for the continuous flow of water in the piping by means
of recirculation, or should provide for the periodic flushing of the system. Experience has shown that
continuously recirculated systems are easier to maintain.

Pumps should be designed to deliver fully turbulent flow conditions to retard the development of biofilms.
Components and distribution lines should be sloped and fitted with drain ports so that the system can
be completely drained. In distribution systems, where the water is circulated at a high temperature, dead
legs and low flow conditions should be avoided, and valved tie-in points should have length-to-diameter
ratios of 6 or less. In ambient temperature distribution systems, particular care should be exercised to avoid
pocket areas and provide for complete drainage. Water exiting from the loop should not be returned to the
system.

To monitor the flow rate in a purified water distribution system today, sanitary vortex, turbine, electrodeless
(capacitance) magnetic, or Coriolis mass flowmeters are used. Other flow instruments are either not sanitary or

60
do not work because of the low conductivity and dielectric constant of the purified water. All these flowmeters
are working very well in this application. Upon closer inspection, the flowmeters listed above still have some
weak points.
• The vortex flowmeter requires a bluff body for its functionality. The bluff body creates a pocket which
cannot be drained completely. In addition, the bluff body creates low flow or even back flow conditions by
design.
• Turbine flowmeters have mechanical moving parts, which can wear out over time. They are hard to clean,
and cannot be sanitized with purified steam.
• The electrodeless magnetic and Coriolis mass flowmeters are expensive.

The role of instrumentation from Endress+Hauser

Endress+Hauser, with a primary focus on process instrumentation, is an innovator for unique product designs
that reduce overall production costs. Just recently, Endress+Hauser introduced the Prosonic Flow, a transit-time
ultrasonic clamp-on flowmeter.

Traditionally, ultrasonic clamp-on flowmeters have a bad reputation. This is based on the performance of meters
that use the Doppler effect to determine the flow rate in such an application. In addition, these devices were not
easy to install and set up.

The new Prosonic Flow meter from Endress+Hauser uses the ultrasonic transit-time effect, which is ideal
to measure the flow rate of purified water. The new flowmeter also addresses the shortcomings of other
designs, to install and set up the instrument. The transmitter of the Prosonic Flow allows connection to two
sets of sensors, and features two current outputs. Additionally, the transmitter can calculate differential flow
rate. With these features and its functionality, the Prosonic Flow is an alternative solution to the traditional
flowmeters.

Advantages offered by Prosonic Flow include:

• No worry about the sanitary integrity because the clamp-on version is non-invasive
• No downtime because the meter can be installed under flow conditions
• Low installation cost, no cutting or welding into a pipe
• No maintenance cost because there are no moving parts

By installing a set of sensors at the beginning of the water loop and one set at the end, the Prosonic Flow can
be validated at anytime. One current output can be set up as a differential flow rate. If no user consumes water
from the water loop, the differential flow rate has to be zero.

Since the Prosonic Flow is a non-invasive

flowmeter, it meets 3-A sanitary requirements,
uses FDA approved materials of construction,
and meets the USP 24 guidelines.

Use of the Prosonic Flow clamp-on flowmeter

greatly improves the reliability, long-term
performance, and stability of the process, while
also significantly reducing the installation
cost in such an application. The end result
– significantly lower cost of ownership.

Prosonic Flow‘s industrial design provides simple, effective, and econo-

mical mounting.

61
Pharmaceutical Industry - Media Preparation

In the Pharmaceutical Industry

Promass Coriolis Mass Flowmeter Plays Crucial Role in the Media
Preparation

In the pharmaceutical and biotech industry, prior to the fermentation- or bio-reactor, a dedicated room is
designed for the media preparation. This area is also known as the batching area.

Process Overview
During media preparation, hydrolysis of proteins and starches takes place, as well as special processing of
steep liquor, molasses, and other crude materials. Very strict accuracy of weights, volumes, pH adjustments,
and processing instructions are the first step to reproducible fermentation results. A uniform quality of
raw materials and adequate equipment are the foundation for a well-run batching area. Equally important
is the detailed batching instructions, and the work of well-trained, reliable personnel. Record keeping of
batch quantities, lot numbers, pH values, temperatures, etc. are necessary for quality production and good
manufacturing practices (GMP).

The plant’s use of continuous sterilizers or batch sterilization determine the size and number of batching tanks.
In the latter case, the difference is that the tanks can be large (50 to 80% of the size of the fermenter), and
usually all the materials are mixed together. For continuous sterilizers, there is normally a minimum of four
smaller tanks so that proteins, carbohydrates, and salts can be batched and sterilized separately. In this case,
the tanks are considerably smaller than the fermenter.

Traditionally, load cells have been utilized as the primary devices measuring the batch quantity of a particular
media. The problems with load cells are:
• Resolution on small batch quantities
• Response time

62
 • Temperature effects
• Accuracy drifts
• Mechanical drifts
• Building stress effects
• High maintenance

Today, more and more companies are starting to use the Coriolis mass flowmeter in combination with load
cells. Since all measurements are taken in weights (lb or kg), it is easy to verify the sum of the individual liquid
ingredients batched through the Coriolis mass meter. The measurement of the solid ingredients added, after
weighing by floor scales, to the total reading of the load cell is also easily verifiable. This instant verification of
the total batch gives a high degree of assurance that the batch is within specification. This combination also
helps to assure reproducible fermentation results.

The role of instrumentation from Endress+Hauser

The use of the Endress+Hauser Promass mass flowmeter for the liquids, and the floor scale for the solids, have
provided outstanding accuracy and even better reproducibility. This has led some companies to eliminate
the load cells completely. In replacing the load cells, customers have added another Promass mass flowmeter
at the outlet of the batch tank for verification purposes. The integrated mass flow, together with the density
measurement, increases the batch reproducibility.

The unique design of the Promass mass flowmeter makes it especially well-suited for the pharmaceutical and
biotechnology industry. Consider the following features:
• Straight through tube design
• Complete drainability
• Medium contact surface finishes better than 240 grit (16 Ra)
• Easy to clean
• In line CIP and SIP cleanable
• Meets 3-A sanitary requirements, uses FDA approved materials, and has passed EHEDG cleanability tests
• No additional mounting required to insure immunity against outside vibration and mechanical stress.

Because the Promass is available with all

these features, it is also used in the following
applications in or around fermenter or bio-
reactor areas:
• Continuous flow rate control of the slow
feed nutrient
• Continuous flow rate control of the anti-
foaming agent supply
• Control of the air, O2, CO2, and N2 gas
flow rate
• Measurement of the outlet gas
• Interphase detection on the fermenter
outlet

The Promass mass flowmeter is a great

contributor toward improving process
reproducibility, increasing productivity, and
significantly lowering the overall cost of
ownership.

Promass M features straight measuring tubes, easy cleaning, and com-

pact construction – allowing easy integration into the plant.

63
Water Industry - Desalination Systems

In the Water Industry

FTL 20 in Desalination Systems - Reliable and Cost Effective Pump
Protection
Our customer is one of the largest Reverse Osmosis Manufacturer‘s in the world. They are a world leader in
water purification and water desalination.

Application
Over the past few years we have sold over 500 FTL 20s
primarily for the desalination systems. They are used in the
pipe for the presence or absence of material.

The signal protects the pumps from running dry. The

signals go to a Process Controller. The pipe sizes are
between 2” and 8”. Most of the piping is PVC.

Liquiphants were used due to their reliability, costs,

materials of construction (316L SS), wire directly into their
PLCs and that the unit requires no calibration.

Obviously, once a customer uses Liquiphant there is no

other choice. ”Fit and Forget”.

64
Wastewater Industry - Fresh and Clean Water

In the Wastewater Industry

Wastewater Treatment in the Textile Industry with Cross Flow
Membrane Filtration

Environmental regulation
Increasing environmental concerns and
regulations have forced many companies
to optimize their use of process water,
as well as the treatment of wastewater.
Recycling of used process water is
becoming a popular way to minimize the
discharge of harmful pollutants into the
environment.

Such an application example exists with

the textile industry where wastewater
from production contains dyes, heavy
metals, and organic chemicals, as well as
textile fibers.

Membrane filtration technology

Membrane filtration is performed by
means of a “Semi Permeable Membrane”. This membrane is permeable only for very small molecules such as
water, but it is impermeable for larger molecules such as dyes and fibers.

The wastewater is pressurized before entering the membrane modules which divides the wastewater into
two streams: cleaned water, and concentrated wastewater. The membranes are cleaned intermittently by CIP
cleaning in order to maintain performance.

Major advantages of membrane filtration

The main advantages of membrane filtration involve the design of the simple modularized process, as well as
the very high quality of the purified water that makes recycling of purified wastewater easy. Therefore, this
system is a very cost effective way to recycle purified wastewater throughout the pharmaceutical industry.

The price for water treatment membrane filtration is often low compared to conventional chemical cleaning
since the price for treatment is mainly decided by the power consumption for the pumps, and the need to
change the membranes. The price for water treatment is typically less than $0.04 per ft.3.

Process control
The system is controlled by measuring the inlet wastewater flow, as well as the purified waste flow. During CIP
cleaning the flow of CIP liquids are measured.

Our solution
For this application the client chose a small diameter Promag 30A. This flowmeter has the right price/
performance ratio for OEM customers.

65
Chemical Industry - Seal Pots

In the Chemical Industry

Liquid Level Switch Ensures Safe Operation in Seal Pot Applications
Nearly every industrial process uses many different Centrifugal
Pump
types of seals to eliminate costly leaks. Modern Sealing Area Motor
chemical production facilities often maintain Coupling

thousands of seal points that are accomplished with a

simple gasket or an o-ring.

When the surfaces to be sealed move relative to one

another – such as the shaft of a centrifugal pump
(see figure 1) – a dynamic seal design must be used
to combat leakage problems. Common dynamic seals Rotating Shaft
are the double and tandem designs that require a
compatible sealing fluid known as the barrier fluid.
External tank assemblies known as seal pots are Figure 1 – The shaft of a centrifugal pump requires a dynamic seal.
commonly used as a source of clean, pressurized
barrier fluid for double or tandem seal assemblies.
These tanks, or seal pots, generally use either a high level or low level liquid switch – sometimes both are
employed (see figure 2).

Process Overview
In a dead-ended system, the fluid is supplied to the seal chamber, providing the positive internal pressure on
the seal to maintain lubrication. In other systems, the fluid may actually be circulated in a closed loop between
the seal pot and the seal chamber.

In both cases, the seal pot is pressurized and instrumentation monitors the
fluid level. Fluid loss results in catastrophic failure of the seal, dangerous
plant conditions, and environmental hazards. Therefore, operators must
rely on a low-level switch to be aware if the fluid level ever drops too
low, indicating a fluid loss problem. Additionally, some applications may
require a high-level switch to indicate hazardous product leakage across
the primary seal and into the seal chamber, adding fluid volume and
raising the seal pot level.

Outputs from these switches connect to alarms and/or plant control

systems, initiating procedures for immediate corrective action. All pots use
a pressure gage, with some systems requiring a pressure switch to activate Figure 2 – A seal pot appli-
an alarm or shut down the pump for added safety. cation using a Liquiphant M
for both high and low level
detection.
Seal design is complex, and proper selection is critical for safe plant
operation. Large offerings of seal designs are available from manufacturers
to suit numerous applications. In addition, an array of suitable barrier
fluids exists to ensure reliable operation.

Since various mechanical seal configurations and fluid combinations can produce widely varying conditions,
safe operation also requires proper selection of the level monitoring instruments, most notably the level switch.

Application Challenges
Under difficult, wide ranging conditions – such as varying viscosity, pressure, temperature, density, dielectric,
air bubbles, and foam – the level detection device’s reliability hinges on its ability to maintain safe operation.

66
Although ultrasonic gap systems, floats, and capacitance instruments have been traditionally used in the
application, these devices are not designed for reliable use as a universal switch under all these possible
conditions. Faulty operation or failure can result if the correct level switch technology is not selected.

The only type of level switch technology designed to withstand all these conditions is the tuning fork design
employed in Liquiphant M, the latest generation of liquid level switches from Endress+Hauser (see figure 3).
With decades of field use and more than 1 million devices installed worldwide, the Liquiphant design has
demonstrated its functionality in the most severe conditions.

A tuning fork is unaffected by foam, air bubbles, vibration, temperature swings,

high pressure, density changes, viscosity changes, buildup, or shifts in the fluid’s
dielectric. No other type of switch technology exists for such universal applicability.
In the absence of moving parts or calibration requirements, there is nothing to wear
out or adjust over the life of the instrument. Therefore, long-term maintenance
issues are minimized.

Various process connections, such as ¾” NPT thread or ANSI flange, are standard.
Available outputs include DPDT relay, 4-20 mA current output, PNP transistor Figure 3 – Liquiphant M‘s
output, 2-wire AC switch, or a Pulse Frequency Modulated (PFM) signal to a remote compact design enables in-
relay-switching unit. Several units are FM approved, Intrinsically Safe, Class I, stallation in small spaces.
Division 1, for installation in hazardous areas.

Others can be installed with Explosion-Proof

housings for Division 1 areas.

Liquiphant M also adds another degree of safety by offering continuous self-

monitoring of both the sensor element and the electronics to signal when
any internal faults are diagnosed.

To meet the stringent demands of the API and ANSI standards for
centrifugal pump seals, minimum requirements exist for the seal pot
instrumentation, including the liquid level switch (see figures 4 and 5). The
API/ANSI data sheets should be written to specifically call out the tuning
fork type of level switch.
Figure 4 – A tandem seal per API Plan
52/ANSI Plan 7352
Considering the typical cost 3' Maximum

of seal pot systems – and

added costs resulting from personal injury, cleanup, fines, and
plant downtime – it pays to have the most reliable liquid level
switch monitoring these fluid levels. For the most reliable seal pot
operation, only a Liquiphant M FTL 50 liquid level switch should be
considered.

12-24"

Secondary Primary
Seal Seal

Figure 5 – A double seal per API Plan 53/ANSI

Plan 7353

67
Fieldgate

Overview

Fieldgate provides a wide variety of solutions for data transfer between transmitters in the field and computer
systems / workstations. In order to understand these options easier, they should be looked at in terms of three
parts of the overall installation.

1) The front end communication between field transmitters and Fieldgate.

2) The data path between Fieldgate and the computer workstation.
3) The visualization approach used within the workstation environment.

Please refer to these three installation parts to identify the desired configuration.

68
Biotechnology Industry - Measuring Cart

In the Biotechnology Industry

Customer Equips Measuring Cart with Promass Flowmeters
This customer has a new product
line (part of a project with a total of
four production units) for a recently
developed biotech product. The parent
company in the U.S. created a patented
solution of injectable hemoglobin. As
this product is independent from blood
groups and rhesus factors, it will be
adopted elsewhere.

The problem involves a decision by the

parent company. The parent company
decided to install mass flowmeters
from a competitor for their first
production line. We had also made an
offer at that time, but it had not been
accepted.

Some time after the installation, the

SCS* calibration was questioned.
The instruments should be calibrated
regularly and, for this purpose,
The measuring cart developed by the customer features a 1 inch Promass and a 2
sent to Flowtec (the only location inch Promass. Both units are explosion-proof.
in Switzerland licensed for SCS*
calibrations). These procedures proved Measuring range:
0 to 660 lb/min
to be very expensive and difficult from
0 to 2500 lb/min
a practical standpoint as some of the
instruments are difficult to access
while production continues.

After long deliberations, the customer wanted to buy two additional instruments and have them calibrated as
reference instruments. The facility is only mounted with 1” and 2” devices.

We offered Endress+Hauser instruments and mounted them on a measuring cart. As a basic condition, our
measuring cart fulfilled the Zone 2 requirements and the explosion proof needs for the instruments.

The customer found this an interesting suggestion and decided to buy a measuring cart. He can also calibrate
the level devices in his tanks with these instruments.

The customer came to Reinach for the inspection and we took the opportunity to show him around in Flowtec
production (including the calibration unit). He was enthusiastic about the measuring cart’s user-friendly
features, and he showed astonishment when he was told that its weight was 661 lbs. All instruments are
mounted on a cart with the Zone 2 user unit. The whole measuring cart has been SCS* calibrated.

*SCS stands for Swiss Calibration Services, which are traceable to national standards.

69
Endress+Hauser Safety
Endress+Hauser Earns Laboratory Approval
Endress+Hauser is certified by Factory Mutual Research Corporation as a qualified FM laboratory, joining only a
handful of companies who have achieved this status.

This certification indicates that Endress+Hauser is qualified to conduct the safety compliance testing of our
products in accordance with FM standards for electrical and electronic test, measurement and process control
equipment. As a qualified FM laboratory, the amount of time between submission and completion of approval is
reduced from about one year to an average of just three to four months.

According to officials, Endress+Hauser is now qualified to conduct all the general purpose tests for our products,
including those which will be submitted to FM for hazardous locations. Products which are developed for
Endress+Hauser in Germany and produced in the United States are covered under this certification.

The relationship between Endress+Hauser and one of the most reputable test agencies in the United States
further strengthens our image in regard to quality and safety.

In Safe Hands . . .
The use of modern instrumentation and control equipment has made a
considerable contribution to the reduction of risks in the process industry, such as
the warning of pressure and temperature buildup and overspill protection.

Increasing levels of employer responsibility, growing environmental pressures, higher raw

materials prices and the increasing cost of unscheduled downtime has resulted in more
stringent safety requirements. As a global supplier, Endress+Hauser takes a proactive
approach to safety issues such as Functional Safety (IEC61508/ IEC61511 as well as ANSI/ISA S84.01), the
ATEX Directive, and the Pressure Equipment Directive (PED), providing our customers with fully compliant
instrumentation.

IEC61508, and IEC61511 attempt to provide a uniform approach to risk assessment and the risk reduction
necessary to ensure safe operation within the chemical industry. Endress+Hauser already produces compliant
devices that can be applied in critical safety instrumented systems in accordance with good engineering practice
for SIS (Safety Instrumented Systems), e.g. our Liquiphant M and S vibrating level switches.

ANSI/ISA S84.01, which is based on IEC61508 (with process sector related differences), presently serves as
the process sector functional safety standard for the US and Canada. Our US customers know that OSHA has
deemed ANSI/ISA S84.01 to be a national consensus standard, considered to be a recognized and generally
accepted good engineering practice for SIS.

The ATEX (Atmosphere Explosive) Directive became mandatory in July 2003. However, Endress+Hauser
instrumentation was already ATEX compliant, offering the maximum in measurement integrity in hazardous
areas. Type approvals from notified bodies permit suppliers to provide a declaration of conformity by placing a
CE sign on all affected products.

The Pressure Equipment Directive (PED) as the name suggests, refers to pressure-bearing equipment.
Endress+Hauser pressure sensors and flowmeters meet the TÜV standard showing that they were manufactured
with “sound engineering practice.”

70
Within the European Union Member States, regulations exist for the application of electrical equipment in an
explosive atmosphere (Ex area). Measurement instrumentation can be used in areas where there is a risk of
explosion, providing they conform to the ignition protection.

IEC International Electrotechnical Commission

ANSI American National Standards Institute
ISA Instrument Society of America
ATEX Atmosphere Explosive
PED Pressure Equipment Directive
SIS Safety Instrumented Systems
OSHA Occupational Safety and Health Administration
CE Conformity European
TÜV Technical Surveillance Association
Ex Explosive Atmosphere

71
Advantages of an Intrinsically Safe Barrier
There are significant advantages in using intrinsically safe instruments, such as Endress+Hauser’s
RN221N Active Barrier, compared to other protection methods such as flameproof or explosion
proof enclosures.
Maintenance of the active system
It is not necessary to establish a gas free zone or
insulate the circuit before calibration or other work
can be performed on the respective devices. Sealed or
magnetically coupled control units that are used on
flameproof or explosion proof enclosures are no longer
required.
Lower cost
Enclosures are lighter and cheaper than other
protection methods. Approved cables, piping,
or conduits can be replaced by simple wiring.
Thermocouples, resistors, switches and other, non-
energy storing passive devices merely have to meet
common requirements. (i.e. weather-proof)
High reliability
The system even remains safe when seals age, cables
are cut (creating an open circuit), leaks occur in the
conduit, or the enclosure covers are opened or no
longer close correctly. One of the basic features of the
RN221N is that the protection continues to be active
even when up to two malfunctions occur in the unit.
Safety
Personnel cannot be harmed by the low voltage and
low current used in intrinsically safe circuits.
72
Variety of applications
Intrinsic safety is the most cost-effective method of
protection which can be applied in Division 1 (high
danger) hazardous areas.
Applying the RN221N Active Barrier
The RN221N can be used in all applications where
two-wire sensors are operating in flammable gases
or dust mixtures.
Typically, the RN221N is mounted in the non-
hazardous area and the split between the supply
voltage and the intrinsically safe voltage occurs in
the device itself. The cables powered by the RN are
then fed into the hazardous areas where they power
the two-wire transmitter. The RN221N transmits
the measured signal received from the hazardous
area to the non-hazardous area equipment. HART
signals are bi-directionally transmitted. The power
supply required for the RN221N is within the range
of 20V to 150V AC/DC.
(Note: It is not customary to mix IS (intrinsically
safe) devices in areas wired with explosion
proof enclosures, conduit and devices due to the
possibility of opening an explosion proof device
while thinking it is an Intrinsically Safe device and
exposing the area to possible ignition.)
Safety instrumented systems

SIL2 / SIL3 rated vibronic point level measurement

devices for overfill protection
A white paper by Endress+Hasuer, Inc

Dr. Christoph A . Rompf

Product Manager Level Measurement
Endress+Hauser GmbH + Co. KG
D-79690 Maulburg, Germany

Key words
Point Level Measurement, Tuning Fork Systems, Vibronic Systems, Level Switches, Safety Integrity Level, SIL,
IEC 61508, ANSI/ISA-S84.01

Abstract
Safety instrumented systems (SIS) that are rated according to the Safety Integrity Levels (SIL) are gaining
importance in the process industry. In this presentation, vibronic point level measurement devices that are
used in highly reliable overfill protection systems, will be discussed. Starting from the basics of how these
tuning fork systems work, the construction principle will be illustrated. With regard to high functional safety,
focus will be placed on the self monitoring capability of vibronic systems and the PFM (Pulse Frequency
Modulation) technology used for signal transmission from the sensor to the switching amplifier.

The combination of these capabilities has led to a SIL2 / SIL3 rating of these sensors for overfill protection
systems according to the international standard IEC 61508 / 61511. The probability of failure on demand (PFD)
requirements according to IEC 61508 fulfilled by these systems are identical to the corresponding American
standard ANSI/ISA-S84.01

Introduction
Liquids are handled in all process facilities. This includes tank farms, food plants, chemical or pharmaceutical
production sites and water and wastewater facilities. Some of these liquids are toxic, flammable, reactive
or cause explosive gases which could cause risks for the environment or personnel. An operator of a facility
or a plant has to assure that these dangerous liquids are kept in the appropriate pipes, tanks and vessels. In
particular, overspilling of a tank has to be avoided during filling processes.

Local laws, government regulations, pollution control agencies or insurance companies require preventive
measures be in place to inhibit tank overruns as depicted in Figure 1, (A) especially during unattended
automated filling process (1). Regardless of the federal and state regulations of any country, automated filling
process always requires a high level alarm that causes an automatic flow shut-off to prevent an overfill. The
reliability and the degree of functional safety of this overfill protection system is related to the potential danger
of the liquid and the surrounding plant or facility.

Overfill protection systems

An overfill protection system is designed to stop product flow during delivery before the tank becomes full and
begins releasing liquid into the environment. As a general rule, such a system consists of a high level sensor,
a logic solver and a final element that shuts off the flow into the tank. Figure 1 (B) shows an example of such
a system. It consists of a vibronic point level measurement device, an appropriate power supply and a switch
amplifier unit in the control room. A Programmable Logic Controller (PLC) or Distributed Control System
(DCS) based logic solver and a supply pipe shut off valve completes the system.

© Copyright 2003 ISA - The Instrumentation, Systems, and Automation Society. All rights reserved.

73
 Fig. 1
(A) Overfilling a tank without overfill protec-
tion
(B) Tank with overfill protection system
consisting of:
(B1) a vibronic high level sensor
(B2) a power supply and switch amplifier
(B3) a Programmable Logic Controller (PLC)
or Distributed Control System (DCS)
(B4) a shut off valve

Failure evaluation with regard to functional safety

The combination of these components has to fulfill the high functional safety demands that are defined in
ANSI/ISA-S84.01 (2) or IEC 61508 (3) and IEC 61511 (4). High functional safety means that these components
either have to work reliably or give an alarm whenever the protection system has to be maintained. Thus,
different types of failures must be defined when a safety system is discussed.

General failures
In general, a system or device is characterized by its “Mean Time Between Failure” (MTBF). That number
represents an average lifetime value for the system or device and includes all failures. With regard to a
functional safety classification, not all failures are relevant. Failures that are detected by the system and can be
announced by an alarm do not lead to critical situations.

Dangerous failures
In comparison to general failures, failures that lead to
a malfunction and are not detected and announced
automatically are dangerous. In the case of an overfill
protection system, that means an operator would
still rely on the system, and in case of a demand, the
system would fail. To track down these “Dangerous
Failures” and to quantify the likelihood of a dangerous
Fig. 2
failure on demand, a “Failure Mode, Effect and Distribution of PFD (Probability of Failure on Demand) values on
Diagnostics Analysis” (FMEDA) is done. The guidelines the components of an overfill protection system
for this are written in the IEC standards 61508 (3) /
IEC 61511 (4) and ANSI/ISA-S84.01 (2). Using these
guidelines, a “Probability of a Dangerous Failure on
Demand” (PFD) can be calculated.

According to the different Safety Integrity Levels (SIL1 thru SIL4), the probability of a Dangerous Failure can
not exceed given values. The exact values are given in IEC 61508 (3) / IEC 61511 (4) and ANSI/ISA-S84.02 (2).

In general, the components of an overfill protection system are purchased from different suppliers. To make
the determination of an SIL classification manageable, the safety considerations can be divided into the
different components. For that process, the PFD values have to be split into different components. A general
recommendation is to weight the PFD value 35% on the sensor system, 15% on the logic solver and 50% on the
final element (Figure 2). Finally, the whole system has to be reviewed. Not only statistical failures need to be
accounted for, but also dangerous systematical failures have to be avoided.

Sensors for Overfill Protection Systems

According to this recommendation, only the sensor for the overfill protection systems shall be discussed and the
means to achieve a high functional safety will be presented.

Point level measurement devices

Point level measuring devices for liquids are used in all process facilities. Numerous measurement technologies
are available for these kinds of applications (e.g. float switches, vibration limit switches, ultrasonic gap switches,
capacitive or conductive limit switches). When considering high functional safety, a measurement method
has to be chosen that has low PFD values and will have no systematical failures during operation. A thorough

74
investigation of the measurement sensor’s systematical failures has to be done or the know-how gained from a
large number of applications has to be considered and a “proven in use” evaluation has to be done.

Vibronic point level measurement devices

Vibronic measurement devices or “tuning fork systems” fulfill the highest demands with regard to safety and
reliability. The main advantage of vibronic point level measurement devices (over float switches, etc.) with
regard to functional safety, is that they use an active measurement principle. The device is kept in vibration
continuously and is always monitored by an evaluation electronics. A sensor failure is detected immediately in
almost all cases and dangerous failures are avoided.

In addition, vibronic measurement devices meet the requirements of almost all point level applications for
liquids (5), (6). A vibronic device is independent of the installation position. The same device can be mounted
from the top, side or bottom. State of the art devices are designed for a broad application band-width where
no calibration of the sensor is necessary. This sensor is independent of process influences (e.g. pressure,
temperature, etc.), independent of material characteristics (e.g. conductivity, dielectric constant, viscosity, etc.)
and independent of gas bubbles, foam and solids (dirt soiling) in the process liquid.

These systems are gaining acceptance as a standard solution for level limit detection in all industries and are
known to work properly in a wide range of applications. Functional safety data can be determined from this
high number of installed units and “proven in use” evaluations can be made.

As an example, the tuning fork system “Liquiphant” distributed by Endress+Hauser has been installed in more
than 1.5 million applications. The product and application know-how created by that amount of installations
has led to a sensor design that is optimized for overfill protection systems and meets the SIL2 level in a 1oo1
(one out of one) and SIL3 level in a 1oo2 (one out of two) or 2oo3 (two out of three) installation architecture.

Operation principle of a vibration limit switch

Mechanically excitable systems are used as vibration limit switches - usually oscillating forks with two tines.
These tines are excited by a piezo drive that converts electrical energy into mechanical energy. A second piezo
acts as a receiver, reconverting the mechanical energy into an electric signal. This electrical signal is amplified,
phase shifted, amplified a second time and fed to the piezo drive. Thus, an electro mechanical loop is set up
that acts as a basic wave excitation and always causes the tines to oscillate with their resonance frequency. The
setup of this basic wave excitation is shown in Figure 3 (A).

Liquid surrounding the tines extends the mass of the resonance system. The frequency is reduced when the
tines are immersed in a liquid.

Evaluation electronics monitor this

frequency shift. Below a certain
frequency, the sensor reports the
covered condition to the evaluation
electronics which indicates the “switch
point”. Typical characteristics showing
the dependence of the resonance
frequency of the depth of immersion is
depicted in Figure 3 (B).

A switch hysteresis of approximately

30 Hz is used between the activation Fig. 3
and deactivation point (f E and f A) to Vibronic measurement devices: (A) basic wave excitation, (B) frequency
reduce sensitivity to state changes. immersion characteristics
This corresponds to a hysteresis of the
switch point of approximately 0.1”. Furthermore, a time delay of approximately 1 second prevents a strong
dependence on turbulent currents and waves on the surface of the measured liquid.

75
Corrosion
In general, corrosion of a sensor is a critical consideration in the application of point level measurement devices
for overfill protection. If improperly managed, corrosion often leads to the state of a dangerous failure. The safe
operation of a passive sensor cannot be ensured because detection of corrosion is not possible.

In contrast, a sensor with a high functional safety has to operate properly, even if it is partly corroded, or the
failure of the function has to be reported to the control system. Vibronic point level measurement devices meet
this demand. Figure 3 (B) shows the behavior of a tuning fork device under corrosive conditions. Corrosion of
the tines causes a loss of mass, thus the frequency is increased. Reaching a certain level resonance frequency
level, a fault alarm is transmitted indicating the point level switch must be replaced.

Typical construction
Vibration limit switches are usually designed in a modular
fashion so that any process connection, housing and
electronic version can be combined in accordance with
customer requirements. Figure 4 depicts the basic design.
The oscillating fork with its piezoelectric drive is attached
to the process connection and the housing adapter via
an extension tube. The housing for the electronic insert
is mounted on top of this arrangement and contains the
power supply, the electronic components of the basic wave
excitation as well as the frequency evaluation system and
Fig. 4
the output interface.
Typical construction of a vibronic point level measurement
device
Transmission via Pulse Frequency Modulation (PFM)
An important functional safety topic is the transmission method used between the sensor and the control
room. Three sensor states have to be transmitted: sensor is uncovered, sensor is covered and sensor fault alarm.
Often, an 8 / 16 mA output level switch is connected directly to a 4 to 20 mA input. As depicted in Figure 5
(A), 8 mA and 16 mA represent the covered
and uncovered sensor situation. A current
of 3.6 mA indicates a sensor fault signal,
e.g. when the sensor is corroded or an
electronic failure occurs.

A current based transmission is safe as

long as the setup is not affected by envi- Fig. 5
Two wire methods for point level measuremet: (A) 8 / 16 mA transmission, (B)
ronmental conditions. Corrosion at the
PFM transmission
contacts can lead to an increase of the wire
resistance and water or humidity on the contacts
may create a parallel resistance. Both can have an
influence on the current and might lead to an uncer-
tain or dangerous transmission condition.

In comparison to this 8 / 16 mA transmission,

the Pulse Frequency Modulation (PFM) shown in
Figure 5 (B) represents a higher safety standard of
transmission via a two-wire line. Here a bias current
of 10 mA is superimposed by current pulses. In this
case, the repetition rate of the pulses and not the
current value corresponds to the sensor condition. Fig. 6
50 Hz corresponds to the covered condition, 150 Hz Block circuit diagram of a sensor and power supply / switch amplifier
the uncovered condition and faults are coded with 0 using PFM transmission
Hz.

The block circuit diagram of a PFM sensor electronic insert and a power supply / switch amplifier is shown in
Figure 6. Apart from the basic wave excitation, it consists of a digital signal processing unit and the electronic
interface. It codes the covered, uncovered as well as the alarm message in an output signal and forwards it to

76
the power supply / switch amplifier unit. In addition, the level switch operating power is derived from the 10
mA bias current.

A calibration EEPROM is integrated into the sensor assembly, in which specific data, such as the exact fre-
quency in air, covered frequency in liquids of 0.5 and 0.7 g/cm3 and further specific data are stored during the
manufacturing process.

Thus it is possible to exchange the electronic inserts to be assured that every sensor unit is equally able to
process the measurement values of all tuning forks precisely without any additional calibration required.

Finally, the power supply / switch amplifier unit in the control room transforms the pulse frequency
signal from the electronic interface into a relay output. The output relays are switched in accordance with
the allocation 50Hz/150Hz; covered/uncovered, or zero Hz; error. In addition, the transmission line is
continuously monitored for line shorts and breakage. Constant monitoring is guaranteed from the sensor tines
to the output of the power supply / switch amplifier.

Applications with extremely high safety requirements demand error-proof systems which operate in safe
conditions in spite of any type of breakdown. Regular inspection and verification of the system is required to
ensure safety.

As a guideline, the overfill protection sensor system has to be function tested regularly (e.g. once a year) to
meet SIL qualifications. Normally, this has to be done by dismantling the sensor and testing it in a liquid or by
filling the tank to the sensor point. This is both expensive and risky, especially when a “dangerous” liquid is
pumped up to the maximum tank level.

Self-check push button

Devices that use PFM transmission technology and have an internal test generator for the manual verification
are allowed to be tested by a push button. In this case, the push button disconnects the wire to the sensor.
After this voltage interruption, the sensor is shortly operated in the self-testing mode once the voltage has been
reconnected, until it automatically switches to the operating mode.

As shown in Figure 6, in a self-testing mode, the frequency of the test generator, instead of the frequency
of the basic wave excitation is connnected to the downstream circuit. The correct interpretation of the
uncovered, covered and error frequencies which might occur (e.g. corrosion) is verified. This ensures the
proper functioning of the measuring system from the tuning fork frequency input to the power supply / switch
amplifier unit. In addition, the manual function test permits the verification of the response of associated
system components, e.g. the sequential control of a shut-off valve or a visual or acoustic alarm.

Concluding remarks
The vibronic point level measurement principle described in this article using PFM transmission between
sensor and power supply / switch amplifier in the control room depicts the highest end of sensor systems
for overfill protection. In this system, the integrated test generator activated by a push button in the control
room provides a comfortable means for the periodic function test required with safety systems. In comparison
to other point level measurement principles, this test does not only evaluate the function of the sensor, but
checks the permanent self check that continuously monitors the frequency of the tuning fork sensor. All these
means have culminated in a vibronic sensor that is SIL3 rated in 1oo2 or 2oo3 installation architectures by the
German TUV (Technischer Ueberwachungs Verein).

However, the sensor is only one part of a complete overfill protection system. The final element, e.g. a shut
down valve, is as important as the sensor to prevent an unwanted release of liquid in the environment. Due
to a high fraction of mechanical parts in these devices, instruments with a similar high functional safety can
be provided only in a very high price segment. Therefore, other means are often taken into consideration to
improve the safety of vessels containing highly hazardous liquids. In consequence, an inexpensive sensor with
a lower functional safety can be chosen. In this case, vibronic point level measurement devices with integrated
relay output can be used. These also use highly “proven in use” components, but go without a separate power
supply / switch repeater.

77
 References
1. WHG Germany: Zulassungsgrundsaetze für Ueberfuellsicherungen (ZG-Ues / May 1999)
Wasserhaushaltsgesetz § 19
2. ISA (1996), ANSI/ISA-84.01-1996: Application of Safety Instrumented Systems for the Process Industries,
Reasearch Triangle Park, NC: The Instrumentation, Systems and Automation Society
3. IEC (1998), IEC 61508, Functional Safety of Electrical/Electronic/Programmable Electronic
Safety-related Systems, Parts 1-7, Geneva: International Electrotechnical Commission
4. IEC (2002), IEC 61511, Functional Safety Instrumented Systems for the Process Industry Sector,
Parts 1-3, (Draft in Progress), Geneva: International Electrotechnical Commission
5. Rompf, Christoph, “Characteristics of Universal Limit Switches for Liquids”,
What is new in process engineering, Melbourne, September 2000, p. 60-70
6. Rompf, Christoph, “Anforderungen an universelle Grenzachalter für Flüssigkeiten”
tm-Technisches Messen; Sensoren, Geräte, Systeme, May 2000, p. 220-227

Measured Data Recording Compliant to 21 CFR Part 11:

Blessing or Curse
Abstract
This paper outlines the 21 CFR part 11 and the requirements laid down by this rule.
It also encompasses the practical requirements on digital data management. We try
to recommend here the necessary requirements for meeting theoretical and practical
requirements and to explain the benefit to industries other than those directly effected.

I. INTRODUCTION

21 CFR 11 – Cause and development

With the requirement for fast, flexible and reliable production, the demands made on systems that analyze,
display and archive information in electronic format constantly increase.

Already many industries put their trust in electronic systems to control, monitor and document their plants and
processes. The older systems based on mechanical and paper based archiving are inadequate for modern plant
data management and monitoring. In today’s digital era where the proliferation of digital systems knows no
bounds it is only logical that we switch to such modern systems.

The increased use of electronic paperless systems like Memograph S leads to reduced direct costs and increased
system efficiency and thereby reduced production costs. Also the powerful electronic data management
systems bring with them modern applications such as integrated supply chain management, E-mail, Satellite
communications and information anywhere, everywhere through the internet.

The inherent advantages bring with them questions and challenges related to data safety. A number of very
important questions remain unanswered, i.e.:
• How safe and secure are the data and sequences documented?
• How reliably can electronic evidence be brought up?
• How trustworthy is the allocation of the responsible person to the electronic recording?

These are questions that are especially relevant to the recording of safety and quality relevant measurement
points in a validation environment.

What is absolutely elementary for such sensitive areas are reliable, reproducible sequences and a clear
evidence of any events or in other words, traceability. Therefore, the following saying is especially valid in the
pharmaceutical industry: “what isn’t documented didn’t happen.“

It must be guaranteed that it is traceable, at any time, who did what and when, and that the responsibility
cannot be avoided due to a system loop hole.

78
So it is not surprising that the “Department of Health and Human Services“ of the FDA (Food and Drug
Administration of America) has decided to deal with the subjects of “Electronic recording“ and “Electronic
signatures“.

It has after long research and after gathering field experience, put together the criteria that a company which
wishes to use the benefits of electronic recording must fulfil. In this obviously the industry looks towards the
experience of data manager manufacturers to come to their rescue and make units that fulfil the criteria and
enables them to enjoy the benefits of modern technology to optimize their processes and reduce production
costs.

II. FDA REQUIREMENTS AND APPLICATION TO PROCESS INDUSTRY

21 CFR 11 – Contents and meaning

The criteria are described in the 21 CFR 11 regulation (CFR = Code of Federal Regulations), which is often also
known as “Part 11“. This regulation is primarily valid for the world wide medication industry, but other related
industries such as laboratories, the cosmetic industry, fine- and bio-chemistry as well as the food and beverage
branches are also subject to the regulation.

This regulation defines electronic records including controls for a system to guarantee authenticity, integrity
and confidentiality of data. Thus it defines electronic signature and document encryption.
The law also specifies that digital signatures must be associated or linked with the records. In industrial process
recorders this is primarily achieved with a so called “Audit Trail” which is explained elsewhere in this paper.

As companies export to all sorts of countries which naturally includes the USA, Part 11 has direct international
influence in pharmaceutical production. It especially concerns the use of instrumentation or systems with
process controlled sequence and recording functions that are used in accordance with the 21 CFR 11, § 11.1 (b)
for creating, changing, maintaining, archiving, reading and transmission of electronic documents.

With the compliance to “Part 11“, electronic records/signatures are given the same legal status by the FDA
as traditional documentation and hand-written signatures. This means no doubt that soon other industries
operating with critical measurement points will play “follow the leader”.

This guideline is the first clear cut definition to bring electronic data storage on par with paper records. This
is the clear advantage to process control and must not be under estimated! This fact makes this paper relevant
across branches such as affluent treatment, chemical processing, oil and gas, manufacturing, quality control,
clean room monitoring and energy.

Filter down effect to other Industries:

So how does it effect the process management in other branches such as Petroleum and chemical? Simple, we
all need safety! Just take the simple example of locks, we all lock our cars, our valuables, we all need to secure
anything that is important to us! Similarly data is important to a process and must be secured! A data manager
is information, and information is power! Power to control quality, power to monitor processes, power to
optimize energy consumption and sometimes power to avoid lurking disaster!

Practical technology introduced in one industry always finds its way to other branches. The filter down effect
with such items due to inherent benefits makes them spread far and wide.

Think about the modern swipe cards, It was developed for military use, now we find them everywhere in the
industry. Also today it is common with all companies of note to talk about

When a batch in production fails because of lack of monitoring or traceability of process conditions, despite
the best installed process equipment, it leads to losses! Why just production, even post production processes
such as transport and storage are extremely critical. Imagine the storage of a chemical, say an epoxy that
hardens/gels above 77°F (25°C) and the humidity is a critical factor. Now if the quality of the chemical must be
guaranteed it must be traceable that it was stored and transported always under 77°F (25°C) and the humidity
levels were below specified levels. Now when using an FDA confirmed recording unit two things are insured,
one the product quality and two the responsible person. Imagine a multi-product plant with round the clock

79
production. Any modern company allows mistakes but not the repetition of mistakes. It becomes important for
the management to zero in on faulting party or process inside the company to avoid future losses.

In every industry today we have very stringent quality standards. The key words in production are zero error,
low down time, energy conservation, cost reduction and high efficiency. The number one tool to achieve
targets is “Reliable Information”. Measured raw data can be converted to reliable information only with reliable
measured data management like with the Memograph S. This is the real goal of electronic documents. This is
where FDA requirements come into relevance for you and your processes. The FDA aims at making electronic
records reliable by using electronic signatures.

21 CFR 11 – Just a question of interpretation?

The 21 CFR 11 became law on August 20, 1997. However the implementation of this regulation in industry has
up to now been very slow.

Now the time has come to make electronic recording and electronic signatures reliable and totally tamper proof.
Preparation for this is an intensive training programm of the FDA inspectors regarding testing and compliance
with the 21 CFR 11. Companies affected will have to reckon with intensive checks in the near future.
Undoubtedly these regulations make electronic recording of processes and sequences far more secure and of
course a lot easier.

Where previously manually created documents consisting of a large amount of paper were required and
identified by a hand-written signature of the responsible person, all that is required now is the unequivocally
allocation of the electronically recorded data to a single responsible person. Additionally all relevant operating
steps and sequences must be documented totally tamper-proof.

The most important benefit for industry is that it can at last use all the advantages of electronic data recording
systems. All the problems that arise using complicated paper recording are now a thing of the past – condition
being that all the regulations of the 21 CFR 11 are complied with.

Now reliable instrumentation such as “Videographic recorders” have been accepted in almost all industries
– even in critical applications. They have now reached a high rate of reliability and recording security.
However if one analyzes the thought behind the 21 CFR 11 it becomes clear that simple software modifications
or optimizing existing instrumentation is not enough to completely cover these strict requirements thus
requiring a complete new development building on the experience of the practical field and merging with FDA
requirements to do it right! Only a few professional companies are thus able to truly speak the language of safe
data management!

The theoretical and practical requirements in the industrial environment- Two sides of a coin.
Memograph S the solution!

An important part of Part 11 is the traceability of sequences. For this each event is saved, manipulation secure,
in the “audit trail” which includes a date and time stamp and the name of the responsible operator at that time.
The latter must be identified by means of a unique, person-allocated “electronic signature”. This means that it
is possible, without any additional work, to safely document relevant operating steps and sequences – and these
are totally tamper-proof thus forming a sort of “flight recorder” for sensitive processes.

Further demands appear when one looks at typical processes in the quality- and safety-relevant measured data:
this mostly concerns the scope of the regulations in plants where various products are produced in different
batches. These generally have specific quality parameters, which means that they must not exceed product-
dependent alarm thresholds. The recording system must be aware of these parameters in order to monitor the
alarm set point conditions to safely document these and react on them if necessary.

Additionally operator changes (e.g. at shift change) must be identified and the requirements of the inspectors
and quality control regarding simple analysis and validation of the process must be taken into account. Because
the operator has to work front-end these systems will always be installed near the process. This of course
increases the need for the units to be made of hygienic, robust material and a very high ingress protection
classification.

80
In order to really fulfil the requirements laid down in the 21 CFR 11, more is required than just making a
password/ID entry and recording possible.

Practical considerations: New concepts are only suitable for application if they cover all the requirements set by
everyone that needs to utilize them. The important aspects:
• Covering the 21 CFR 11,
• Practice orientated use in operational environments,
• Completely wear-and-tear and maintenance-free data recording and archiving, as well as
• Simple handling of the record by quality control and the FDA inspectors.

Complete compliance with the 21 CFR 11 means that there must be a user and rights maintenance system
integrated in the unit. Each user identifies himself using a unique combination of ID and password, the
“electronic signature” that is only known to him (and the Data Management unit). This way the unit can
differentiate between different users and their access rights. Mechanisms that call upon the user to cyclically
change the password avoid safety-critical familiarity effects. The users must be trained and informed that this
form of signature is legally accepted by the FDA in the same way as a hand-written signature on paper.

The electronic signature provides the basis of the FDA requirements. Further, the system then must document
process sequences in the so called “audit trail” that is manipulation free and tamperproof. In this record
operating steps are automatically archived including the allocation of the responsible person and the message
created by the unit (e.g. power down recognized). Additionally all these events must be “date and time
stamped” thus enabling them to be listed in the time sequence (chronological order) that they occurred.
In the practical world typical working practices (e.g. shift change) as well as changing access rights (e.g. new or
leaving staff) are also taken into account without ignoring the requirements of Part 11.

A further element here is the electromechanical concept of the unit. FDA specifies certain certified plastics
or stainless steel keeping in mind the environments in food and drug production. A front bezel that is
corrosion free enables the unit to be installed in any environment and protects it from mechanical damage and
manipulation. Even if Part 11 does not make any clear statement on this point it is obvious that unauthorized
manipulation by persons that cannot be clearly identified goes against the basic concept of 21 CFR 11. This
important point is also seen as such by experienced quality inspectors.

Furthermore, the connection terminals are secured by a back cover in the Memograph S as this is the point of
data reception. If a plant or process has been validated then the following sequences must always deliver the
same expected results. Changes to the signal inputs would be counteracting this demand. Any changes that
may occur must be logged in the audit trail. Plant operators, QA personnel and inspectors can now, thanks to
the Memograph S, have the highest security and reliable evidence that validated processes continuously deliver
the expected results. The Safety Data Manager Memograph S is designed to make life easier in the industry and
the data secure. The stainless steel housing is easy to clean and has a shatterproof front

Conclusion
When a really suitable system complying to 21 CFR 11 is selected to record, monitor and intelligently evaluate
measured data it proves to be a blessing for all branches of industry. Consider the Endress+Hauser Memograph
S that combines the requirements set out in Part 11 with the practical functionality required by your process.
Look for built-in software features to simplify checks made by Quality Assurance and inspectors. Get yourself
a partner that offers not just units but complete solutions, understands not just laws but also customer
requirements and industrial processes. In short get yourself a solution that offers 100% practicality in addition
to data reliability through complete compliance with Part 11.

Madhukar Puniani & Dieter Schmidt

Endress+Hauser Wetzer GmbH
Obere wank 1
Nesselwang 87484

Dieter Schmidt
Endress+Hauser Wetzer GmbH
Obere wank 1

81
Explosion Protection in Process Automation
*Article used with permission of Business Briefings Ltd.

82
83
84
85
86
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87
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88
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89
 Your source for the measurement
and component products you need
Level • Pressure • Temperature • Analysis • Components

Spec ia l
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90
Glossary of Instrumentation Terms
Absolute Pure Water Water with a specific resistance (resistivity) of 18.25 MΩ•cm at 25°C.

Absorption Process by which one substance is taken up by another, either chemically or

physically.

Accuracy The degree to which an indicated value matches the actual value of a measured
variable. Normally characterized in percent and indicative of maximum
measured error likely to occur under specified conditions.

Acidity The concentration of base required to raise the sample pH to an arbitrarily

defined value in a particular method. The acidity of a solution is not an
equivalent measurement to its pH, which is a measurement of the activity of the
hydrogen ion.

Activity (ai) A thermodynamic term for the apparent or active concentration of a free ion in
solution. It is related to concentration by the activity coefficient.

Activity Coefficient (fi) A ratio of the activity of species (i(ai)) to its molarity (C). It is a correction factor
which makes the thermodynamic calculations correct. This factor is dependent
on ionic strength, temperature, and other parameters.

Individual ionic activity coefficients, f+ for cation and f- for an anion, cannot be
derived thermodynamically. They can be calculated only by using the Debye-
Huckel law for low concentration solutions in which the interionic forces depend
primarily on charge, radius, and distribution of the ions and on the dielectric
constant of the medium rather than on the chemical properties of the ions. Mean
ionic activity coefficient (f±) or the activity of a salt, on the other hand, can be
measured by a variety of techniques such as freezing point depression and vapor
pressure as well as paired sensing electrodes. It is the geometric mean of the
individual ionic activity coefficients:

f± = (f+n+f–n–)1/n
Alarm A device with an audible or visible signal that indicates an abnormal or out-of-
limit condition in a plant or control system.

Alkalinity Capacity of water to accept protons (H+ ions), i.e., its acid neutralizing capacity).

Alpha Numeric A character set that contains both letters and digits and usually other characters,
such as punctuation marks.

Ambient Pressure The pressure of the medium surrounding a device.

Ambient Temperature The temperature of the environment surrounding a particular location.

Ampere The unit measure of current (also referred to as “amp”).

Amplifier In process instrumentation, a device that enables an input signal to control power
from a source independent of the signal and thus be capable of delivering an
output that bears some relationship to, and is generally greater than, the input
signal.

91
Analog The continuous and observable representation of a variable reflecting any and all
changes in value. An AC or DC signal that varies continuously over time.

Analog to Digital Converter (AD)

An electronic device that converts an analog input of electric voltage or current
into a proportional digital signal.

Angstrom Ten to the minus tenth meters (10-10) or one millimicron, a unit used to define the
wave length of light. Designated by the symbol A.

Anion A negatively charged ion (CI-, NO3-, S2- etc.)

Aqueous In water or water based.

Area Classification A method of rating process areas for their susceptibility to an explosion.
Locations are classified according to the properties of flammable vapors, liquids
or gases, or combustible dusts or fibers which may be present, and the likelihood
that a flammable or combustible concentration or quantity is present. As defined
in the National Electrical Code, process areas are categorized by three classes,
seven groups, and two divisions.

ASIC Application Specific Integrated Circuit - a chip containing a tailor made circuit for
a specific function.

Asphyxian A vapor or gas that displaces oxygen, causing unconsciousness or death by

suffocation.

Associated Apparatus Electrical apparatus in which the circuits are not all intrinsically safe but which
contains circuits that can affect the safety of intrinsically safe circuits connected
to it. An intrinsic safety barrier is a type of associated apparatus.

Baseline In some analytical procedures the sample is dissolved in water or combined with
other reagents for analysis. A “blank” or standard consisting of the same reagents
may be analyzed without sample present. This provides a comparative reference
point, or baseline, so that test result can be atrributed solely to the sample itself.

Bluff Body The non-streamlined obstruction placed in the flow stream for the purposes of
generating vortices. Also known as the shedder bar.

Boiler The vessel used in distillation or power distribution systems to convert water into
steam.

Buffer A solution that is capable of opposing small changes in chemical composition;

particularly in pH.

Buffer Capacity (B) A measure of the ability of the solution to resist pH change when a strong acid or
base is added.

Calibrate Calibration is the process of determining the initial accuracy of a device by

applying carefully quantified inputs to the device, registering the output for each
input, comparing the measured output to a standard, and accordingly adjusting
the instrument.

Calibration Traceability The relationship of the calibration of an instrument through a step-by-step

process to an instrument or group of instruments calibrated and certified by a
national standardizing laboratory.

92
Cation A positively charged ion (Na+, H+).

Caustic 1) An alkaline (pH greater than 7) corrosive.

2) The common name for NaOH.

Cell Constant In a conductivity cell, a constant that characterizes the cell geometry as a ratio
between the electrode area and the effective volume of solution (A/V).

Characterization The ability of a smart transmitter to compensate for ambient temperature

changes, non-linearities, and other outside influences.

Chlorination The process in water treatment of adding chlorine (gas or solid hypochlorite) for
purposes of disinfection.

Circuit Board A flat sheet on which integrated circuit components are mounted.

Class A category for classifying a hazardous area; there are three classes, each of which
identifies the generic nature of the hazard present, gas, dust or fibers.

Combined Zero Shift and Span Error

An instrument error evidenced by a change in the zero value and by a difference
between actual span and ideal span.

Combustible Liquid A liquid with a flash point between 100° and 200°F.

Combustion Triangle A model for understanding how an explosion is caused. The three sides of the
combustion triangle are fuel, ignition source, and oxygen.

Compressed Gas Any material contained under pressure; i.e., dissolved gas or gas that has been
liquefied by compression or refrigeration.

Compressibility The ability of a substance to expand or contract in volume when acted upon
by either temperature or pressure. Liquids are normally considered non-
compressible by pressure. They do expand and contract to a limited degree in
volume depending on their temperature. Gases are compressible and their volume
is greatly affected by changes in pressure, and temperature.

Compressibility Factor A correction factor numerically expressing the behavior of a real gas under
stated temperature conditions, with respect to its deviation from Ideal Gas Law
behavior.

Condensate Distillate just after it has been cooled from steam into the liquid state.

Conductance The measure of the ability of a solution to carry an electrical current.

Conduction The conveying of electrical energy or heat through or by means of a conductor.

Conductivity The reciprocal of resistivity, it is a measure of the ability to conduct an electric

current. Since ionized impurities increase the conductivity of water, it is also an
accurate measure of ionic purity. To measure it, current is passed between two
electrodes a fixed distance apart. Conductivity is normally expressed as Siemens/
cm.

Conformity 1) Of a curve, the closeness to which it approximates a specified curve.

2) Degree to which a process, practice or device conforms to established
standards.

93
Control Drawing A manufacturer-provided circuit diagram illustrating the allowed
interconnections for intrinsically safe apparatus, associated apparatus, and other
equipment.

Controller A device or program that operates automatically to regulate a controlled variable.

Corrosive A chemical that causes visible destruction or irreversible alterations in living

tissue or construction materials by chemical action at the site of contact.

CPU Central processing unit. That portion of the electronics that manages the control
of all circuits, computation, communications and outputs.

Creep Suppression See Low Flow Cutoff (1).

CSA Canadian Standards Association. A testing agency located in Canada that reviews
and tests instruments to certify that they may be safely used in hazardous areas
without causing an explosion. See also FM.

Current The measure of electrical charge flow rate between points of unequal voltage,
in amperes (A). The most common range of transmission signal for electrical
process control instruments is 4 to 20 mA DC.

Damping The progressive reduction or suppression of oscillation in a device or system.

Deadband In process instrumentation, the range through which an input signal may be
varied, upon reversal of direction, without initiating an observable change in
output signal. Usually refers to switch of discrete outputs.

Deadweight Tester A device used to generate pressures for the purpose of calibrating pressure
instruments and gages. Freely balanced weights (dead weights) are loaded on a
calibrated piston to produce a static hydraulic or pneumatic pressure output.

Decade Resistance Box A device that provides precision resistance values in units expressed as ohms.

Decimal System A numbering system with ten as its base. It has ten digits, 0 through 9, in its
written form.

Deionization Removing dissolved ions from solution by passing it through a bed of ion
exchange resins, consisting of polymer beads that exchange hydrogen ions for
cations and hydroxyl ions for anions in solution. The ionic impurities remain
bound to the resins, and the hydrogen and hydroxyl ions combine with each
other to form water.

Demineralization Sometimes used interchangeably with deionization, it refers to the removal of

minerals and mineral salts using ion exchange.

Density The mass of a substance per unit volume. Often expressed in terms of pounds per
cubic foot.

Desalination The removal of dissolved salts from brine to produce potable water.

Deviation The difference between the value of a specific variable and some desired value.

94
Dielectric Constant An attribute that every material has, expressed in units of Farads/meter, that is
indicative of the material’s influence on an electric field. Often denoted as: DC,
DK, epsilon, e, or e0.

Differential Pressure The difference between the pressure at any two defined points.

Differential Pressure Transmitter

Any of several transducers designed to measure the pressure difference between
two points in a process and transmit a signal proportional to this difference,
without regard to the absolute pressure at either point.

Diffusion Random thermal motion of particles which cause them to flow from a region
of higher concentration to one of lower concentration until they’re uniformly
distributed.

Digital Representation of system variables by a limited number of discrete values.

(Compare to analog.)

Digital Signal A series of pulses or voltage levels that vary in discrete or separate steps.

Digital to Analog Converter (D/A)

An electronic device that converts a digital signal, often from a computer, into a
proportional analog voltage or current.

Dilution Lowering the concentration of a solution by adding more solvent.

Disinfection The treatment of water to inactivate, destroy, and/or remove pathogenic bacteria,
viruses, protozoa, and other parasites.

Dissociation Constant (K) A value which quantitatively expresses the extent to which a substance
dissociates in solution. The smaller the value of K, the less dissociation of the
species in solution. This value varies with temperature, ionic strength, and the
nature of the solvent.

Dissolved Oxygen Refers to the measure of elemental oxygen (as solute) dissolved in water (as
solvent). Common indicator of suitability of water condition for beneficial
biological activity.

Dissolved Solids Also referred to as Total Dissolved Solids (TDS), it is the amount of nonvolatile
matter dissolved in a water sample, and is usually expressed in parts-per-million
by weight.

Distillation The process of separating water from its impurities by heating until it changes
into vapor, and then cooling the vapor to condense it into purified water.

Distortion An undesired change of a signal.

Division One means of classifying a hazardous area; there are two divisions, based on the
amount of time that hazardous materials are present in the area.

Dosimeter A type of personal monitor used to detect and monitor exposure to radiation
levels.

Download A data or program transfer, usually from one computer to another.

95
EHEDG European Hygienic Equipment Design Group. Made up of representatives from
research institutes, food industry, equipment manufacturers and European
government organizations. The EHEDG develops guidelines and test methods for
safe and hygienic processing of food.

Electrode In the process measurement context, an electrode is a metal, or semiconductive

structure with the specific purpose of being an electrical contact point (circuit
termination point) for sensing electrical potential or current. In analytical
measurement, it refers to an entire assembly which contacts the process, normally
utilizing a permeable membrane or glass between the process and the circuit
termination point.

Electrode Potential (E) The difference in potential established between an electrode and a solution when
the electrode is immersed in the solution.

Electrolyte Any substance which, in solution, will conduct an electric current. Acids, bases,
and salts are common electrolytes.

Emergency Response Team

A specifically designated team trained to respond to chemical spills, leaks, and
exposures.

Encapsulation An explosion prevention method in which the ignition source is embedded in a

solid or semisolid medium such as plastic, ceramic, or tar, thus separating the
ignition source from the flammable atmosphere.

Energy-storing Apparatus A piece of equipment that contains energy-storing devices such as capacitors
and transformers, and must therefore be certified for use in an intrinsically safe
system.

Entity Approval A type of certification for an intrinsically safe system in which each intrinsically
safe apparatus is evaluated separately, as are the associated apparatuses. Each
component can be connected as desired as long as the electrical parameters of the
individual devices are maintained.

EPDM An elastomer made from ethylene-praylenediene monomer. This compound has

good abrasion resistance and excellent chemical resistance to a variety of acids
and alkalines.

Equivalent Conductance (I)

Equivalent conductance of an electrolyte is defined as the conductance of a
volume of solution containing one equivalent weight of dissolved substances
when placed between two parallel electrodes 1 cm apart, and large enough to
contain between them all of the solution. I is never determined directly, but
is calculated from the specific conductance (Ls). If C is the concentration of a
solution in gram equivalents per liter, then the concentration per cubic centimeter
is C/1000, and the volume containing one equivalent of the solute, is therefore,
1000/C. Since Ls is the conductance of a centimeter cube of the solution, the
conductance of 1000/C cc, and hence I, will be.

Error The difference between the indicated (or measured) value and the true value of
the parameter being measured.

Expansion Factor A factor used to compensate for changes in density of gases that do not follow the
Ideal or Perfect Gas Laws. Also known as the “Z” factor.

96
Explosion Proof Enclosure
A case that is capable of withstanding an explosion of a specified gas or vapor
which may occur within it, while also preventing the ignition of a specified gas
or vapor surrounding the enclosure by sparks, flashes, or explosion of the gas
or vapor within. Operates at such an external temperature that a surrounding
flammable atmosphere will not be ignited thereby.

Explosive A material that produces a sudden, almost instantaneous release of pressure, gas,
and heat when subjected to abrupt shock, pressure, or high temperature.

Feedwater Water entering a treatment process.

FEP A thermoplastic Teflon® resin developed in 1960 (fluorinated ethylenepropylene).

It can be melted, extruded and fabricated by conventional methods.

Field Mounted An instrument mounted at the measurement, or in the plant, rather than in the
control room.

Filling Solution A solution of defined composition to make contact between an internal element
and a membrane or sample. The solution sealed inside a pH glass bulb is called
an internal filling solution. This solution normally contains a buffered chloride
solution to provide a stable potential and a designated zero potential point. The
solution which surrounds the reference electrode internal and periodically
requires replenishing is called the reference filling solution. It provides contact
between the reference electrode internal and sample through a junction.

Filtration Removal of suspended matter by passing it through a porous matrix that prevents
particles from passing through, usually by entrapment on or in the filter matrix.
A water treatment step used to remove turbidity, dissolved organics, odor, taste
and color.

Flame path A flat joint on an explosion proof enclosure, that is constructed by accurate
grinding or machining of the mating surfaces of the cover and body. The surface
of the body and the surface of the cover are bolted closely together so that flames
and hot gases forced through the openings are cooled by the mass of the metal
enclosure.

Flammable Gas A gas that at ambient temperature and pressure forms a flammable mixture
with air at a concentration of 13% by volume or less; or a gas that at ambient
temperature and pressure forms a range of flammable mixtures with air greater
than 12% by volume, regardless of the lower limit.

Flammable Liquid A liquid with a flash point below 100°F.

Flammable Solid A solid that ignites readily and continues to burn or is liable to cause fires under
ordinary conditions, or during transportation through friction, or retained heat
from manufacturing or processing. Burns so vigorously and persistently as to
create a serious hazard.

Flammable Any solid, liquid, vapor, or gas that ignites easily and burns rapidly.

Flanged Body Style A meter with flanges integral with the meter body, used to connect the meter
body to the pipeline. They are available in 150, 300 and 600 ANSI Class as
required for the application.

97
Flash Point The lowest temperature at which a flammable liquid gives off sufficient vapor to
form an ignitable mixture with air near its surface or within a vessel.

Flow Conditioner A device that is inserted in the pipeline upstream of a flowmeter for the purpose
of providing the proper flow profile necessary to obtain accurate measurement. It
is only required when there is not sufficient space to permit the normally required
straight pipe ahead of the flowmeter.

Flow Rate The quantity of fluid passing a fixed cross section of a pipe in a unit of time,
divided by that time.

Flume One type of primary device. A narrowed restriction built into, or inserted into,
an otherwise unrestricted open channel. During flow conditions, liquid level
downstream of the flume will be lower than the level of liquid upstream. That
differential in level is measured to infer flow rate.

FM Factory Mutual, an organization that reviews and tests instruments, against the
standards they develop, to assure that they will not cause a fire or explosion when
properly used in a hazardous area.

Fouling When gelatinous coatings, colloidal masses or dense bacterial growth form a
compacted crust on membrane or filter surfaces or electrodes, preventing proper
operation.

Frequency 1. The number of cycles a periodic variable passes through per unit time.
2. Rate of signal oscillation in units of hertz (Hz).

Gain The ratio of the change in output over the change in input which caused the
change.

Galvanic Pertaining to electrical potential resulting from chemical processes.

Ground A conducting connection, whether intentional or accidental, between an electrical

circuit or equipment and the earth, or to some conducting body that serves in
place of the earth as an “infinite electron accepter”.

Group A subcategory for classifying a hazardous material; each of the seven groups
specifically identifies a range of material types within the defined Class.

Hardness Concentration of calcium and magnesium salts in water. High hardness can
cause boiler or pipe scale and failure of reverse osmosis membranes.

Hazardous Area An area in which explosive atmospheres are, or may be expected to be, present in
quantities such as to require special precautions for constructing and using
electrical apparatus.

Hazardous Material A substance that can pose an unreasonable risk to health and safety, property, and
the environment.

Hermetic Sealing A method of creating a seal through fusion (e.g., soldering, brazing, welding, or
fusion of glass to metal) around a device to prevent the entrance of an external
atmosphere.

Hertz (Hz) A measure of the frequency in terms of cycles per second.

98
Holder Also called an electrode holder or armature. A mechanical element that serves
the purpose of mounting an analytical sensor. Retractable versions also facilitate
cleaning, replacement or calibration.

Hydrogen Ion Activity (aH+)

Activity of the hydrogen ion in solution. Related to hydrogen ion concentration
(CH+) by the activity coefficient for hydrogen (f H+).

Hysteresis 1) The difference in the indicated quantity (output) for a given input, depending
on whether the input resulted from an increase or decrease from the previous
value.
2) Sometimes used to describe the difference between an alarm on and off point
— more correctly called “deadband”.

Hysteresis (Electrode Memory)

When an electrode system is returned to a solution, equilibrium is usually not
immediate. This phenomenon is often observed in electrodes that have been
exposed to other influences such as temperature, light, or polarization.

IDLH An atmospheric condition determined to be Immediately Dangerous to Life or

Health.

Immersion An explosion prevention method in which the ignition source is immersed in

an inert material, such as oil, sand, or an inert gas, thus separating the ignition
source from the flammable atmosphere.

Inches of Water Usual term for expressing a measurement of relatively low pressures or
differential pressure. (For example, 1” of water equals 0.36 psi; 1 psi equals
27.703” of water.)

Input Signal A signal applied to a device, element, or system. Incoming signal to measuring
instrument, control units, or system.

Installation Effect An external influence causing spurious or biased outputs from instruments.
These may be of a mechanical, electrical, thermal, chemical or other nature.

Instrument In process measurement and control, this term is used broadly to describe any
device that performs a measuring, controlling, recording, or computing function.

Integral An amplifier circuit board mounted on the instrument body.

Interface An electronic device that provides a communication link between other devices
or circuits.

Internal Reference electrode (Element)

The reference electrode placed internally in a glass pH electrode.

Intrinsic Safety A method of explosion prevention in which circuits operate at energies so low
that any spark or thermal effect is incapable of igniting a mixture of flammable or
combustible material in air under prescribed test conditions.

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Intrinsic Safety Barrier (ISB)
A device or system of devices that will, when properly installed, render any
circuit intrinsically safe provided: (1) no power sources greater than the barrier
rating are applied to the unclassified side of the ISB, (2) no outside power sources,
including other intrinsically safe systems, are applied to the hazardous area side
of the ISB, and (3) there is no energy-storing system in excess of the maximum
permitted by the ISB on the hazardous side. ISBs commonly have resistors that
limit current and Zener diodes that limit voltage.

Ion An atom or group of atoms with an electrical charge that is positive (cation) or
negative (anion) as a result of having lost or gained electrons.

Ion Exchange Also called deionization. A process in which harmless ions attached to resin
beads are exchanged for undesirable ions in solution. Typically, hydrogen ions are
exchanged for any cations and hydroxyl ions for any anions. The hydrogen and
hydroxyl ions combine to form pure water.

Ionic Mobility Defined similarly to the mobility of nonelectrolytic particles, as the speed that the
ion obtains in a given solvent when influenced by unit power.

Ionic Strength The weight concentration of ions in solution, computed by multiplying the
concentration of each ion in solution (C) by the corresponding square of the
charge on the ion (Z) summing this product for all ions in solution and dividing
by 2: ionic strength - 1/2 ∑ Z2 C.

Irritant A noncorrosive material that causes a reversible inflammatory effect on living

tissue by chemical action at the site of contact as a function of concentration or
duration of exposure.

Isopotential Point A potential which is not affected by temperature changes. It is the pH value at
which dE/dt for a given electrode pair is zero. Normally, for a glass electrode and
SCE reference, this potential is obtained approximately when immersed in pH 7
buffer.

Junction Potential The potential developed at the liquid/liquid junction between the reference-
electrode filling solution and the sample solution. For accuracy, the junction
potential should be as small and as constant as possible despite variations in the
composition of the sample solution.

Kalrez® A perfluoroelastomer which exhibits elastomeric properties, plus outstanding

chemical resistance. Kalrez can be used successfully in many applications
where dependable long-term service is desired and in high temperature and/
or aggressive environments which are beyond the serviceability of common
elastomers.

K-Factor The factory calibration setting which is determined to provide best accuracy for
a particular flowmeter under test. The number of pulses or vortices shed per
unit volume (See “Calibrate” and “Calibration”.) Also sometimes referred to as
calibration factor.

Kynar® Also known as PVDF (polyvinylidene fluoride), a moldable, machineable resin

material with excellent material compatibility used for liners and seals.

Linear A straight-line relationship between one variable and another. When used
to describe the output of an instrument, it means that the output is directly
proportional to the input.

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Linearity The closeness to which a curve approximates a straight line. It relates to a
calibration curve (the average of upscale and downscale readings) and is usually
expressed as the deviation (non-linearity) between the curve and a straight line.

Liquid Junction The potential difference existing between a liquid-liquid Potential boundary. The
sign and size of this potential depends on the composition of the liquids and the
type of junction used.

Lockout/Tagout A procedure of de-energizing, locking, and labeling an energy-isolating device

for a piece of equipment to be worked on to ensure that it will stay de-energized
while personnel work on it, and that catastrophic injury will be avoided.

Logarithmic Scale A method of displaying data (in powers of ten) to yield maximum range while
keeping resolution at the low end of the scale.

Loop Approval A type of certification for an intrinsically safe system in which individual
intrinsically safe apparatus are evaluated in combination with selected associated
apparatuses and are approved to be installed in that manner. Any further
modification to the circuit requires reevaluation.

Low Flow Cutoff 1) Flowmeter output adjustment feature whereby low accuracy flow rates
(typically very low flows) are “forced” to “zero flow”. This removes uncertainties
in totalization and control where non-zero measurements during “no flow”
conditions might occur - such as from sloshing or process noise.
2) Inherent low flow measurement limitation - e.g. in a vortex shedding
flowmeter, where below a certain flow rate, vortices are not created.

Lower Explosive Limit The lowest acceptable level of combustible gases or vapors in an atmosphere
before it would be considered too dangerous for personnel to work in that area.

Lower Range Limit (LRL) The lowest value of the measured variable that a device can be adjusted to
measure.

Lower Range Value (LRV) The lowest value of the measured variable that a device is adjusted to measure.

Mass In the strict sense, mass (measured in kg) is a constant-value attribute assigned
to matter which indicates the ratio between an object’s acceleration and the force
required to produce that acceleration. However, it is common in industry to use
“mass” interchangeably with “weight”, since these two variables are directly
related, by a simple conversion factor, when the mass in question is terrestrial,
and when gravity is considered constant. As such, units of weight (lbs, oz) are
often used to indicate “mass”.

Mass Flow Rate The amount of fluid, measured in mass units (rather than volumetric units) that
passes a given location or reference plane per unit of time. In practice, industrial
users may be interested in expressing mass flow in “weight per unit time” units.
(Also see Mass.)

Material Safety Data Sheet (MSDS)

A data sheet, provided by the manufacturer of a chemical, that provides detailed
information on a chemical, including its properties, dangers, handling and storage
procedures, and emergency response procedures.

Measured Error See Error.

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Megohm-cm Unit of measure of ionic purity in water. Resistivity (the reciprocal of
conductivity) is a measure of specific resistance to electrical flow. The fewer
dissolved ions in water the higher its resistivity. One megohm-cm is equivalent
to one million ohms of resistance measured between two electrodes (area/cm 2)
spaced one centimeter apart. The theoretical maximum ionic purity of water is
18.25 megohm-cm at 25°C.

Membrane The membrane makes contact with and separates the internal element and filling
solution from the sample solution. The pH-sensitive glass bulb is the membrane
across which the potential difference is developed, due to the formation of double
layers with ion-exchange properties on the two swollen glass surfaces.

Memory Any form of computer data storage.

Meter Factor Pertaining to flow metering: the number of pulses generated per unit volume (or
unit mass) or fluid being metered.

Molality A measure of concentration expressed in moles per kilogram of solvent.

Molarity A measure of concentration expressed in moles per liter of solution.

Mole The amount of substance that contains as many molecules as there are atoms in
12 grams of Carbon 12. There are approximately 6.0221367 x 1023 molecules per
mole.

Molecular Weight The weight of a molecule that may be calculated as the sum of the atomic weights
of its constituent atoms. (Atomic weight is the weight of an element in relation to
some element taken as the standard, usually oxygen (16) or carbon (12).)

Monitor A device to sample the atmosphere in a work area. Portable monitors check for
gas or oxygen before personnel enter the work area, or can provide continuous
monitoring while work is being done. Personal monitors worn by personnel can
act either as detectors that begin beeping or flashing when certain conditions
start to occur, or as cumulative exposure badges. Both types of monitors are used
to detect oxygen content, radiation, toxicity, or combustible gases or vapors.

Multimeter A test instrument having different ranges for measuring voltage, resistance, and
current flow (in milliampere range) in electrical or electronic circuits. Also
known as circuit analyzers; volt-ohm-millimeter OVOM); multiple purpose
meter; DVM.

National Fire Protection Association (NFPA)

An international, voluntary, membership organization to promote and improve
fire protection and prevention and establish safeguards against loss of life and
property by fire.

Nernst Equation A mathematical description of the behavior of electrochemical electrodes.

NFPA Hazard Rating System

A system, devised by the National Fire Protection Association, for identifying the
hazards associated with a particular substance. It divides hazards into four
color-coded hazard categories – blue for health, red for flammability, yellow for
reactivity, and white for special hazards. Each hazard is rated on a basis from
0 to 4, with 0 being the least hazardous and 4 being the most hazardous.

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NIST (formerly NBS) National Institute of Standards and Technology, formerly known as the National
Bureau of Standards.

Noble Metal One of the chemically inert metals.

Noise An unwanted (and seemingly random-varying) component of a signal or variable

which obscures the information content.

Non-incendive A type of equipment and wiring which in its normal

operating condition would not ignite a specific
hazardous atmosphere. (Such equipment may be used only in Division 2 areas.)

Non-linearity A type of error, where the input to a device does not relate to the output in a
linear manner; indicated on a calibration chart as a curve or curves.

Nonvolatile Memory Computer memory that retains data when power is removed.

Normal Conditions 1) A term frequently found when operating conditions are given in metric units.
The temperature is 0°C and 1 Bar as opposed to standard conditions of 60°F and
14.7 PSIA. May also be referred to as Standard Conditions.
2) May refer to the lack of abnormal conditions in a process or device, to describe
the nature of the operating environment relative to hazardous locations concerns.

NTU Turbidity in water is measured in units called NTUs or Nephelometric Turbidity

Units. Also equivalent to FTUs and FNUs.

Offset A constant and steady state of deviation of the measured variable from the set
point.

Ohm The practical unit of electrical resistance in a circuit, where a potential difference
of one volt produces a current of one ampere.

Operating Conditions The fluid properties of specific gravity, viscosity, density, temperature and
pressure at which the instrument will be expected to perform its meter function.

Operational pH The determination of sample pH by relating to pH measurements in a primary

standard solution. This relationship assumes that electrode errors such
as sensitivity and changes in asymmetry potential can be disregarded or
compensated for, provided the liquid junction potential remains constant between
standard and sample.

Organic Organic matter is a broad category that includes both natural and man-made
molecules containing carbon and hydrogen. All living matter in water is made up
of organic molecules. The most common are by-products of vegetative decay such
as tannins, lignins and humic acid.

Orifice Plate One type of primary device. Typically a round plate, with a sharp-edged hole
in its center. Mounted between flanges, this type of restriction (hole smaller
than the pipe diameter) creates a pressure drop between the upstream and
downstream sides of the plate. The differential pressure from one side of the plate
to the other is measured to infer flow rate. Various hole sizes and positions serve
specific application purposes and flow measurement ranges.

O-ring A toroidal sealing ring made of synthetic rubber or similar material. The cross
section through the torus is usually round or oval, but may be rectangular or
some other shape. Normally used to avoid dependence on tightening forces, as
gaskets require.

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ORP Abbreviation for oxidation-reduction potential. A type of analytical measurement
that determines the oxidizing or reducing state of a chemical reaction; it applies
to any chemical reaction which exchanges electrons. Also known as “Redox”.

OSHA Occupational Safety and Health Administration.

Osmosis The diffusion of a solvent through a semipermeable membrane from a less

concentrated solution to a more concentrated solution.

Output Signal The signal provided by an instrument; for example, the signal that the controller
delivers to the valve operator is the controller output.

Oxidizer A substance that yields oxygen readily to stimulate the combustion of organic
matter.

Particulate Usually a solid particle large enough to be removed by filtration. Nonfilterable

solids are usually referred to as colloids.

PFA An advanced Teflon® resin developed in 1972, capable of being molded or

extruded.

pH An analytical measurement of the activity of hydrogen ions in a solution; an

indication of the degree of acidity or alkalinity of an aqueous solution. The pH
scale is logarithmic.

pH Glass Specially formulated glass which provides a varying potential based upon the
concentration of hydrogen ions.

pH Junctions The junction of a reference electrode or combination electrode is a permeable

membrane through which the fill solution escapes (called the liquid junction).

pH(S) (Standard pH Scale)

The conventional standard pH scale established on the basis that an individual
ionic activity coefficient can be calculated from the Debye-Huckel law for primary
buffers.

Polarity (1) The particular state either positive or negative with reference to the two poles
or to electrification.
(2) Having positive and negative poles.

Polarization The inability of an electrode to reproduce a reading after a small electrical current
has been passed through the membrane. Glass pH electrodes are especially prone
to polarization errors caused by small currents flowing from the pH meter input
circuit and from static electrical charges built up as the electrodes are removed
from the sample solution, or when the electrodes are wiped.

Potable Suitable for drinking.

Potentiometric Any method that produces a voltage (potential) with little or no current flow.

PPB Parts per billion, or micrograms per liter.

Preamplifier An electronic board in a sensor that converts a high impedance primary signal
into a low impedance signal that can be stably transmitted extended distances.

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Pre-Chlorination The addition of chlorine to the water prior to any other plant treatment processes.

Precipitate When a solution reaches saturation, solute will begin to come out of solution, as
when water precipitates from saturated air as rain.

Precision The degree of reproducibility among several independent measurements of the

same true value.

Pressurization The addition of air or inert gas into the enclosure around
electrical equipment at sufficient pressure to prevent entry of contaminants.

Primary Device Pertaining to flow measurement; a mechanical device designed to restrict flow for
the purpose of creating a known mathematical relationship between the flow rate
and some other measurable variable, for the purpose of inferring flow rate from
the 2nd variable. Examples are an orifice plate for closed pipe flow inferred by
pressure drop, and a flume for open channel flow inferred by level differential.

Process-Wetted Materials Any part of a sensor or other instrument which comes in direct contact with the
process fluid. In this context, may also refer to contact with dry process materials.

Profile Distortion Velocity profile distortion is the change in the axial velocity profile from that
expected in a fully developed condition. This fully developed condition exists
only in the long, straight pipe runs, or downstream of flow conditioners (which
are designed to promote fully developed flow conditions for metering purposes).

Protocol A set of conventions which governs the way in which devices communicate with
each other.

psi Abbreviation for pounds per square inch.

psia Abbreviation for pounds per square inch, absolute.

psig Abbreviation for pounds per square inch, gauge.

PTFE The original Teflon® resin invented in 1938, polytetrafluoroethylene. It does not
flow like other thermoplastics when melted, and must be shaped by techniques
similar to powder metallurgy.

Purging The addition of air or inert gas into the enclosure around the electrical equipment
at sufficient flow to remove any hazardous vapors present and sufficient pressure
to prevent their re-entry.

Purification Removal of impurities of concern. It has one meaning when applied to the
preparation of drinking water, another when applied to reagent grade water for
the laboratory, and still another when applied to water used to rinse integrated
circuit devices.

Quantization Error Error of an instrument which may result from indicated values that can only
change in discrete steps such as in digital measurement, or in analog outputs
driven by digital devices. Also see Resolution.

Radioactive Material A material that spontaneously emits alpha, beta, or gamma rays by the
disintegration of the nuclei of atoms.

Random Error An error in measurement that varies in a random manner with time.

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Range The extent of a measuring, indicating, or recording scale; beginning with the
lower range value and ending with the upper range value.

Rangeability The ratio of the maximum measurement to the minimum measurement rate of a
meter. Accuracy tolerance limits and operating conditions must be specified.

Reactivity A substance’s tendency to undergo chemical reaction either by itself or with

other materials with the release of energy. A reactive material polymerizes,
decomposes, condenses, or becomes self-reactive due to shock, pressure, or
temperature.

Redox Potential The potential developed by a metallic electrode when placed in a solution
containing a species in two different oxidation states. See also ORP.

Reference Electrode That half of a pH or ORP electrode pair which provides a constant potential
regardless of solution composition. The potential developed by the sensing
electrode is measured against this reference potential to give an overall system
potential which can be converted as a measure of the species sensed.

Refractive Index An optical property of a medium, arising from its dielectric properties. Equal to
the ratio between the wavelength of an electromagnetic wave in a vacuum and
its wavelength in the specified medium. (Also may be calculated as the ratio of
the respective wave velocities). Since there is a relationship between this ratio
and the light-bending characteristic of the specific medium, refractive index is
normally determined by optical detection of the angle of the refracted light. Also
known as Index of Refraction.

Relative Dielectric A unitless quantity which expresses the ratio of a Constant material’s “true”
dielectric constant relative to the dielectric constant of a vacuum (~8.85 pF/m).
Correctly denoted as er, but often denoted, in practice, as DC,
DK, epsilon, or e. Also see “Dielectric Constant”.

Remote Converter Electronics for an instrument that are located away from the instrument body.

Repeatability The closeness of agreement among a number of consecutive measurements of

the output for the same value of the input under the same operating conditions,
approaching from the same direction.

Reproducibility The closeness of agreement among repeated measurements of the output for the
same value of input made under the same operating conditions over a period of
time, approaching from both directions.

Re-ranging The process of assigning different upper and/or lower range values to a
transmitter. This does not meet the strict definition of “calibration”, but
instrument users may refer to re-ranging as calibrating.

Resistance Temperature Detector (RTD)

A sensor consisting of wire which changes its resistance as a function of
temperature. The resistance-temperature relationship is well-established so
that a specific resistance can be interpreted as a predictable measurement of
temperature.

Resistivity A measure of specific resistance to the flow of electricity. In water, it is an

accurate measure of ionic purity.

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Resolution The smallest detectable increment of measurement. Resolution is usually limited
by the number of bits used to quantize the input signal. For example, a 12-bit DA
can resolve to one part in 4096 (2 to the 12 power equals 4096).

Reverse Osmosis (RO) The reversal of osmosis to purify water. In osmosis, water diffuses through
a semipermeable membrane from a less concentrated solution to a more
concentrated solution. The flow of water can be reversed with an opposing
pressure that exceeds osmotic pressure. With RO, water is forced out of a
concentrated solution, leaving the solute (impurities) behind.

Reynolds Number A dimensionless number taking into account the flowing velocity, fluid density
and viscosity and the pipe cross sectional area. It provides a means to predict the
flow profile of the fluid within the pipe under flowing conditions.

Right-to-Know Law OSHA’s Hazard Communication Standard, which mandates that employers
inform employees of hazardous materials on-site through training, labeling, and
material safety data sheets.

RTD Abbreviation for resistance temperature device. A temperature-sensing device

that provides temperature information as the change in resistance of a metal wire
element, often platinum, as a function of temperature.

RTD transmitter A device that converts resistance value from an RTD to a standard instrument
signal (such as 4-20 mA) that can be communicated within a measurement
control loop.

Secondary Standard pH buffer solutions which do not meet the requirements of primary standard
solutions but provide coverage of the pH range not covered by primary standards.
Used when the pH value of the primary standard is not close to the sample pH
value.

Sedimentation The process of suspended solid particles settling out (going to the bottom of the
vessel) in water.

Sensor A generic name for a device that detects either the absolute value of a physical
quantity or a change in value of the quantity and converts the measurement
into a useful input signal for an indicating or recording instrument. Also known
as primary detector; sensing element.

Set Point An input variable which sets the desired value of the controlled variable. It may
be manually set, automatically set, or programmed, and it is expressed in the
same units as the controlled variable.

Shedder Bar See Bluff Body.

Simple Apparatus Those items in an intrinsically safe system which do not generate or store more
than 1.2V, 0.1A, 20uJ, and 25mW. Because of their low energy requirements,
simple apparatus can be used in intrinsically safe systems without certification.
For practical purposes, such apparatus are almost always resistive in nature;
having low, or no, capacitive or inductive components.

Smart Transmitter A microprocessor-based transmitter with its own memory and logic circuits that
enables it to do a larger array of functions as compared to a conventional
transmitter.

Solute The substance that dissolves to form ions in solution.

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Solution A liquid that contains dissolved solute.

Solvent A liquid capable of dissolving a solute.

Span The algebraic difference between the upper and lower range values. Thus, a
temperature in the range of 68°F (20°C) to 482°F (250°C) has a span of 446°F
(230°C).

Span Adjustment Means provided in an instrument to change the slope of the input-output curve.

Span Error The difference between actual span and ideal span, usually expressed as a percent
of ideal span.

Span Frequency The frequency of vortex shedding at the span setting (at 20 mA).

Span Velocity The velocity of the flow at the span setting (20 mA). Normally expressed in terms
of feet per second.

Species Refers to a specific variety or form of chemical compound or radical; all the
members of a given population of such a chemical entity.

Specific Gravity The ratio of mass of any material to the mass of the same volume of pure water at
39.2°F (4°C).

Standard A measurement device that is certified and referenced to values established by the
National Institute of Standards and Technology (NIST). See Calibration
Traceability.

Standard Electrode Potential (EO)

The standard potential EO of an electrode is the reversible emf between the
normal hydrogen electrode and the electrode with all components at unit activity.

Standard Thermometer A highly accurate certified thermometer used as a reference standard for checking
or calibrating temperature instruments.

Standardization A process of equalizing electrode potentials in one standardizing solution (buffer)

so that potentials developed in unknown solutions can be converted to pH values.

Strouhal Number The ratio between the vortex interval (distance between vortex swirls) and vortex
shedder width. Usually the vortex interval is about six times the vortex shedder
width. When the Strouhal number is fixed, the flow velocity can be measured by
counting the vortices.

Swirl The local variation from true axial velocity, predominantly caused by the
interaction of various pipe fittings. Swirl is a three dimensional property and is
basically rotation of the fluid within a channel or pipe.

Systematic Error An error in measurement that has a fixed relationship to the true value of the
parameter being measured.

Teflon® A class of fluorocarbon resins commonly used as a liner or seal material. Known
for its chemical inertness, Teflon® can also be used in a wide range of
temperatures and has a low coefficient of friction.

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Tefzel® An advanced fluoropolymer resin. Tefzel® has inert properties exceeding
Teflon® resins, but has a more limited temperature range to a maximum of
300°F.

Temperature Coefficient The change in output to be expected per °F of the ambient temperature.

Terminal Box A small housing mounted on top of an instrument body. It is only required when
the converter is mounted remotely. Its purpose is to provide a junction box for
the wires coming from the sensor and the cables to the remote converter.

Thermistor A temperature-measuring device, similar to a resistance temperature detector,

made of heat treated metallic oxide.

Thermocouple A temperature sensing device composed of dissimilar thermoelectrically

homogeneous wires, joined at one end to form a measuring junction. From
a thermocouple, a voltage, or EMF (electromotive force) is produced if a
temperature gradient exists between the measuring junction and the reference
junction.

Thermocouple Transmitter
A device that converts millivoltage output from a thermocouple to a standard
instrument signal (such as 4-20 mA) that can be communicated within a
measurement control loop.

Threads A continuous helical rib, as on a screw, pipe, or case cover either tapered or
parallel.

Threshold Limit Value (TLV)

An indication of the airborne concentration of a chemical to which nearly all
workers can be exposed day after day without adverse effects.

Toxins Substances that attack biological functions, causing illness or death. Acute toxins
produce toxic effects after a single exposure. Chronic toxins produce toxic
effects after repeated exposures over time.

Transducer An element or device which receives information in one form of energy and
converts it to information as another form of energy (e.g. pressure transducer
converts mechanical force to electrical energy).

Transmitter An instrument that responds to a measured variable by means of a sensing

element and converts it to a standardized transmission signal, whose value is a
function of the measured variable.

Turbidity The inferred measurement of small particles (e.g. soil, sand) of solid matter
suspended in water.

Turndown The factor by which a transmitter’s full scale output (Upper Range Value) may
be reduced, relative to the Upper Range Limit, and still maintain the specified
accuracy.

Type X Purge Purging adequate to reduce the classification of an area within an enclosure from
Division 1 to unclassified.

Type Y Purge Purging adequate to reduce the classification of an area within an enclosure from
Division 1 to Division 2.

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Type Z Purge Purging adequate to reduce the classification of an area within an enclosure from
Division 2 to unclassified.

Ultrapure Water Water with a specific resistance (resistivity) higher than 1 megohm-cm. In the
laboratory, it usually refers to type one reagent grade water.

Ultraviolet That portion of the electromagnetic spectrum below blue light (380 nanometers).

Uncertainty An estimate characterizing the range of values within which the true value lies;
with a stated probability.

Unclassified Area Also called a safe or nonhazardous area. An area in which explosive mixtures
are not expected to be present so that special precautions for the construction and
use of electrical apparatus are not required.

Upper Range Limit (URL) The highest value of the measured variable that a device can be adjusted to
measure.

Upper Range Value (URV) The highest value of the measured variable that a device is adjusted to measure.

Velocity The speed at which a fluid travels within a pipe. Usually defined in terms of feet
per second.

Velocity Profile A variation in local axial velocities across the diameter of a pipe section.

Viscosity The property of a fluid, resulting from molecular cohesion, that enables it to
develop and maintain an amount of shearing stress dependent upon the velocity
of flow and then to offer continued resistance to flow.

Volume The amount of space occupied by a three dimensional figure as measured in cubic
units.

Viton® A fluoroelastomer material which exhibits good chemical resistance, used

primarily as a seal material.

Voltage Electrical potential or potential difference expressed in volts. Symbolically

represented as V or U.

Volumetric Flow Fluid flow that is metered in volumetric units such as gallons or cubic feet
without regard to the weight or mass per unit volume.

Volumetric Flow Rate The volume of fluid moving through a pipe or channel per unit of time; such as
100 gallons per minute.

Von Karman Vortex Street

The pattern of vortex swirls being shed from the bluff body. Named after T. Von
Karman who did considerable research on the vortex shedding phenomenon in
the early days of the 20th century.

Wafer Body Style Instrument body held in the pipeline by a clamping between the mating flanges
by long tie bolts and nuts. The meter body itself does not have flanges, but relies
on the clamping pressure to seal against leakage.

Water Column (W.C.) See Inches of Water.

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Water Hammer A brief condition within a closed system (typically pipe) in which an abrupt halt
in the flow of any liquid (as might result from the closing of a valve) creates a
pressure “spike”. Such brief high pressure conditions are a common, but difficult-
to-diagnose, cause of damage to pressure sensors.

Weir One type of primary device. A notched barrier (plate) installed across the
end of an otherwise unrestricted open channel, at the point where the channel
discharges into a much larger reservoir or holding “box”. During flow conditions,
liquid level in the notch is measured to infer flow rate.

Zero Adjustment Means provided in an instrument to produce a parallel shift of the input-output
curve, normally used to compensate for zero shift.

Zero Shift An unwanted condition caused by a shift in the instrument calibration, evidenced
by a change in the zero value.

111
112
Compatibility Tables and
Conversion Charts

113
 Chemical Name Temp 1 Platinum Tantalum Hastalloy SS316L PFA Hard Rub Soft Rubb PU Temp 2 Platinum Tantalum Hastalloy SS316L PFA Hard Rub Soft Rubb PU Temp 3 Platinum Tantalum Hastalloy SS316L PFA Hard Rub Soft Rubb PU
Acetaldehyde 100% § Ethanal 100% 20 A A A A A B B C 100 U A A A A C C C

114
Acetic acid 1,5% non areated 20 A A A B A A A C 80 A A A B A B B C 120 A A B C A C C C
Acetic acid 5% 20 A A A A A A A C 80 A A A A A B A C 100 A A A A A C B C
Acetit acid 10% non areated 20 A A A A A A A C 80 A A A A A B B C 100 A A A B A C C C
Acetic acid 10-50% non areated 20 A A A B A A B C 80 A A A B A C B C 120 B A B B A C C C
Acetic acid 20% 20 A A A A A A B C 80 A A A A A B B C 100 A A A B A C C C
Acetic acid 30% 20 A A A A A A B C 80 A A A A A B B C 120 A A A B A C C C
Acetic anhydride 99-100% 20 A A A B A A A B 80 A A A B A C B C 120 B B B C A C C C
Acetone § Dimethylketone 20 A A A B A B A C 80 A A A B A C B C
Air 20 A A A A A A A A 50 A A A A A A A A 80 A A A A A A A A
Alum 10% 20 A A B B A A A B 100 U U U U U U U U
Aluminum chloride 10% 20 A A A C A A A B 100 A A A C A B B B
Aluminum chloride 25% 10 A A A B A A A B 80 A A A C A B B B 100 A C A C A B B B
Aluminum sulfate 10% 20 A A A A A A A B 80 A A A A A A A C 150 U A A B C C C C
Aluminum sulfate 100% 20 U A B B A A A B 80 U A B B A A A C 150 U A C C C C C C
Ammonia (Gas) 20 A C A A A B B C 80 U C A A B B B C 120 U C A A C C C C
Ammonia 100% 20 A C B A A A A B 100 U C B B A C A C
Ammonium bromide 10% 20 A A C A A U A U 80 A A C C A U B U 120 C A C C B U C U
Ammonium carbonate 30% 20 A A A B A A A A 80 A A B C A B B C 120 U B C C C C C C
Ammonium chloride 20% § Sal ammoniac 20% 20 A A A C A A A A 80 A A A C A B B B 150 C C C C C C C C
Ammonium fluoride 20% 20 A C A C A A A U 80 U C B C A C B U 100 U C C C A C C U
Ammonium hydroxide § Caustic ammonia 20 A A B A A A A A 80 A C C A A U U C 100 A C C A A U U U
Ammonium nitrate 20% 20 A A B A A A A B 80 A A B A A A A C 100 A A C C B A A C
Ammonium nitrate 50% 20 A A B A A A A B 80 A A B A A A A C 100 A A C C C A A C
Ammonium sulfate 60% 20 A A B C A A A A 80 A A B C A A A B 100 A A C C A B B C
Aniline § Aminobenzene 100% 20 A A A B A B A C 80 A A A B A C A C 120 A A B C B C B C
Animal fat 20 A A A A A A C B 80 A A A A A A C C 150 A A A A A C C C
Argon (Gas) 0 A A A A A A A A 20 A A A A A A A A 50 A A A A A A A A
Arsenic acid 10% 20 A A B B A A A C 80 A A B C B B B C 120 U A C C C C C C
Arsenic acid 100% 20 A A B B A U U C 80 A B B B U U U C 120 A B B C U U U C
Arsenic acid 40% 20 A A B B A U U C 80 A A B C U U U C 120 U A C C U U U C
Barium chloride 20% 20 A A A B A A A A 80 A A A C A A A B 100 A A A C A B B C
Barium hydroxide 10% § Caustic baryta 10% 20 A A B B A A A A 80 A A C C A B B C 120 B B C C B C C C
Beer 20 A A A A A A A C 70 U A C A A U U C 100 U A C B A U U C
Benzene 20 A A B B A C C C 50 A A B B A C C C 100 A A B B C C C C
Benzenesfulfonic acid 100% 20 A A B B A A B C 80 A A B C A A C C 100 A A C C A B C C
Benzoic acid <50% 20 A A A B A A B C 80 A A A C A A B C 120 A A U C B B C C
Boric acid 10% 20 A A A A A A A A 80 A A A A A A A C 120 A A A A A C C C
Boric acid 50% 20 A A A B A A A A 80 A A A B A B B C 120 A A A C A C C C
Brine 7% 20 A A A B A A A C 100 A U B B A A U C
Brine 13.6% 20 A A A B A A A B 80 A U A B U A C C
Brine 23.1% 20 A A A B A A A B 80 A U A B A A C C
Bromine dry 100% 20 C A A C A C C C 80 C A B C B C C C 120 C A C C C C C C
Bromine wet 100% 20 U A A C A C C C 80 U A A C A C C C 120 U B B C B C C C
Butadiene 1,3 100% 20 A A A A A C C C 80 A A A A A C C C 100 A A A A A C C C
Butane (Gas) 0 A A A A A C C B 20 A A A A A C C B 50 A A A A A C C C
Butyl acetate 100% 20 A A A A A C C B 80 A A A A A C C C 120 B A A A A C C C
Butylalcohol § Butanol 20 A A A A A A A C 80 A A A A B B B C 120 A A A A C C C C
Butyric acid 100% 20 A A A B A B B C 80 A A A B A C C C 120 A A A B B C C C
Calcium bisulfite 20 A A B A A B C A 80 U A B A A C C C 120 U A B A C C C C
Calcium hydroxide + water § Milk of lime 20 A A A B A A A C 80 A A A B A B A C 100 A A B B A C C C
Calcium nitrate 10% 20 A A B B A A A C 80 A A B B A A A C 120 U U U C B C C C
Calcium sulfate 1-5% § Gypsum 1-5% 20 A A B B A A A B 80 U A B B A B A C 120 U A C C A C C C
Calcium sulfate 10% § Gypsum 10% 20 A A B B A A A B 80 U A B B A B A C 120 U A C C B C C C
Carbon dioxide (Gas) 20 A A A A A B B A 50 A A A A A B B B
Carbon dioxide liquid -30 A A A A A A B B 0 U A A A A A B B 20 U A A A A A B C
Carbon disulfide 20 A A B B A C C C 80 A B B B A C C C 100 A B B B A C C C
Chemical effluent 20 A A B B B B B B
Chloral 100% 20 U U A A A C C U 80 U U A A U C C U 120 U U U U U C C U
Chlorine (Gas), dry 20 A A A B A C C C 80 U U C B C B C C 120 U U C C C C C C
Chloroacetic acid 100% 20 A A B B A A A C 80 A A B C B B B C 120 U A B C C C C C
Chloroacetic acid 50% 20 A A B B A C B C 80 A A B C A C C C 120 U A C C B C C C
Chlorobenzene mono 100% 20 A A A B A C C C 80 A A A B A C C C 120 B A A C B C C C
Chlorosulfonic acid 80-100% 20 A A A B A C C C 80 A A B C A C C C 120 A A B C A C C C
Chocolate 55 A A A A A C C A
Chromic acid 10% 20 A A B C A A C C 80 A A C C A C C C 120 A A C C A C C C
Chromic acid 50% 20 A A B C A A C C 80 A A B C A C C C 120 U A C C A C C C
Citric acid 50% 25 A A A A A A A A 80 A A A A A B B C 150 U A B B A C C C
 Chemical Name Temp 1 Platinum Tantalum Hastalloy SS316L PFA Hard Rub Soft Rubb PU Temp 2 Platinum Tantalum Hastalloy SS316L PFA Hard Rub Soft Rubb PU Temp 3 Platinum Tantalum Hastalloy SS316L PFA Hard Rub Soft Rubb PU
Concrete 25 A A A A C C C C
Copper (2) chloride 20% 20 C A C C A A A B 80 C A C C A A A C 120 C B C C A C C C
Copper (2) chloride 50% 20 C A A C A A A B 80 C A B C B B A C 120 C B C C C C C C
Copper ore slurry 20 U U U A U U A U
Copper sulfate 5% § Romane vitriol 5% 20 A A A A A A A B 80 A A A A A A A C 120 U B A B B C C C
Corn oil § vegetable oil 20 A A A A A A C A 80 A A A A A B C C 120 A B A A C C C C
Dichloroethylene 100% § Vinylidene chloride 20 A A B B A C C C 80 A A B B A C C C 120 B B C C B C C C
Dichloropropane 1,2 20 A A U A A U C U 80 A A U A C U C U 150 B B U A C U C U
Dimetylanilin § Diethylaniline 20 A U U A A B B C 80 A U U A A B C C 120 A U U B B C C C
Dioxane § Diethylendioxide 20 A A A A A C B C 80 A A C A A C C C 120 B B C B B C C C
Diphenyl 100% § Phenylbenzene 20 A A A A A C C C 80 A A A A A C C C 120 A A A A B C C C
Ether 20 A A B A A C B B 100 A A B A A C C C
Ethyl acetate § Acetic ether 90-100% 20 A A A A A C A C 80 A A A A A C B C 150 A A B B A C C C
Ethyl alcohol § Ethanol 20 A A A A A A A C 80 A A A A A C A C
Ethyl chloride moist 20 A A B A A B C C 80 A A B A A B C C 120 B B C B A C C C
Ethyl clorid § Cloroethane 100% 20 A A A A A B C B 80 A A A A B C C C 120 A A A A C C C C
Ethylene 20 A A A A A B C B 80 A A A A C B C C 150 A A A A C C C C
Ethylene glycol § Dihydroxyethane 100% 20 A A A A A A A B 80 A A A A A B B C 120 U B B B C C C C
Ethylene oxide 20 A A A A A B C C 80 A A C B A C C C 120 B B C B A C C C
Fatty acid 20 A A A A A C C B 80 A A A A A C C C 120 A A A A B C C C
Ferric (2) sulfate 10% 20 A A B A A A A B 80 A A C A A B B U 120 B B C B C C C U
Ferric chloride 30% 20 C A B C A A A C 80 C A C C A A A C 120 C B C C U B B C
Ferric chloride 40% 20 C A C C A A A C 80 C A C C A A A C 120 C B C C A B B C
Ferric nitrate 30% 20 A A B B A A A B 80 A A C B U U U C 120 U U C C U U U U
Formaldehyde 20% § Formic aldehyde 20% 20 A A B A A B A B 80 A A B A A C A C 120 A B C C B C B C
Formic acid 1% 20 A A A C A A A C 80 A A C C A B B C
Formic acid 10% 20 A A A B A A A C 80 A A B C A C C C 100 U A C C B C C C
Formic acid 50% 20 A A A B A A A C 80 A A B C A C C C 100 U A C C B C C C
Formic acid 80% 20 A A A B A C C C 80 A A B C A C C C 100 U A C C B C C C
Furfural § Furfuraldehyde 20 A A C B A C B C 80 A A C B A C C C 120 A A C B B C C C
Gasoline 20 A A A A A C C B 80 A A A A A C C C 150 U A A B C C C C
Glycerine § Glycerol 20 A A A A A A A B 80 A A A A A B B C 120 B B B B B C C C
Helium (Gas) 0 A A A A A A A A 20 A A A A A A A A 50 A A A A A A B B
Hexane 20 A A A A A A C B 90 A A A A A C C C
Hydrazine <50% 20 A A C A A U A C 80 C C C B C U A C 120 C C C C C U C C
Hydrobromic (Gas) 20 A A B A A C A C 60 A A C A C C C C 100 A A C A C C C C
Hydrochloric acid 1% § Muriatic Acid 1% 20 A A A C A A A C 50 A A A C A A C C 100 A A C C A C C C
Hydrochloric acid 1.5% § Muriatic Acid 1.5% 20 A A A C A A A B 80 A A C C A A C C
Hydrochloric acid 5% § Muriatic Acid 5% 20 A A A C A A A B 80 A A C C A B B C 120 A A C C A C C C
Hydrochloric acid (Gas) § Muriatic Acid (Gas) 20 U A A C A A A C 80 U A B C A C C C 150 U C C C C C C C
Hydrochloric acid 10% § Muriatic Acid 10% 20 A A A C A A A C 50 A A B C A A A C 100 A A C C A B C C
Hydrochloric acid 25% § Muriatic Acid 25% 20 A A B C A A A C 80 A A C C A A C C 120 A A C C A C C C
Hydrocyanic acid 10% § Hydrogencyanid 10% 20 A A A B A B A C 80 A C A B A C B C 120 B C B C B C C C
Hydrofluoric acid < 40% 20 A C C C A C C C 80 A C C C A C C C 120 B C C C A C C C
Hydrogen (Gas) 20 A B A A A A A A 80 A C A A A A A C 150 U C A A A C C C
Hydrogen peroxide 20% 20 A A A B A A B C 80 A A C B A C C C 100 A A C B A C C C
Hydrogen peroxide 70% 20 A A A A A C C B 80 A A C C A C C C 150 U A C C A C C C
Iron sulfate 10% § Ferric sulfate 20 A A A A A A A C 80 A B C C A A U C 150 U C C C C C U C
Isobutylalcohol 20 A A A A A A A C 80 A B B A A C B C
Isopropanol § Isoproyl alcohol 20 A A A A A A A C 80 A A A A A A C C
Kerosine (JP4) 20 A A A A A C C C 60 U U B A A C C C 100 U U B B A C C C
Lactic acid 10% 20 A A B B A A A B 80 A A B B A A A C 120 U A C C B B B C
Lime slurry wet 20 A A A B A A C A 50 U U A B A A C C 120 U U B C C C C C
Magnesium chloride 20% 20 A A A A A A A A 80 A A A B A A A C 120 A A B C A B B C
Magnesium sulfate 25% 20 A A A A A A A C 80 A A B A A A A C 120 A A C B A B B C
Malic acid 20% 20 U A B A A A C C 70 U A B A A A C C 100 U B C B C B C C
Malt extract 20 U U U A A U A C
Manganouse chloride 20% § Manganese 20% 20 B A B B A A C B 80 B A B B A A C C 120 C B C C A B C C
Manganouse sulfate <50% § Manganese <50% 20 A A A A A A A A 80 A A A A A U A C
Methane (Gas) § Natural gas 20 A A A A A C C B 80 A A A A A C C C 100 A A A A A C C C
Menthyl alcohol 20 A A A A A C A B 80 A A A A A C B C
Methylenechloride 80-100% § Dichlorometh- 20 U A A B A C C C 80 U A A B A C C C 100 U A A C B C C C
ane 80-100%
Methylethylketone 20 U U A A A C A C 80 U U A A A C C C
Milk 20 A A A A A A B C 70 A A B C A A C C 100 A A B C A B C C
Molasses § Treacle 20 A A A A A A A B 80 A A B A A A A C 100 A A B A A A A C
Monochloroacetic acid 20 U A A A A C C C 80 U A A C A C C C 120 U A A C B C C C
Naphthalene § Naphtaline 20 A B B A A A C A 80 A B B A A C C C 120 A B C A A C C C
Naturresin § Rosin 20 U A A A A U C A 80 U A A B A U C C 120 U A A B A U C C

115
 Chemical Name Temp 1 Platinum Tantalum Hastalloy SS316L PFA Hard Rub Soft Rubb PU Temp 2 Platinum Tantalum Hastalloy SS316L PFA Hard Rub Soft Rubb PU Temp 3 Platinum Tantalum Hastalloy SS316L PFA Hard Rub Soft Rubb PU
Nitric acid 1.5% § Azotic acid 1.5% 20 A A A A A A A C 80 A A B A A C C C 120 A A C C A C C C

116
Nitric acid 10% § Azotic acid 10% 20 A A A A A A A C 70 A A B A A C C C 120 A A C B A C C C
Nitric acid 20% § Azotic acid 20% 20 A A A A A A A C 70 A A B A A C C C
Nitric acid 30% § Azotic acid 30% 20 A A A A A A B C 70 A A B A A C C C
Nitric acid 60% § Azotic acid 60% 20 A A A A A C C C 80 A A C C A C C C 120 A A C C A C C C
Nitrobenzene § Oil of mirbane 20 A A B A A C C C 80 A A B A A C C C 120 U U C A A C C C
Nitrogen (Gas) 20 A A A A A A A A 50 A A A A A A B B
Nitrogen liquid -160 A A A A A A A A 0 A A A A A A A A 20 A A A A A A A A
Nitrohydrochloric acid § Aqua regia 20 C A C C A B C C 80 C A C C A C C C 120 C A C C A C C C
Oleum 25% § Fuming sulfuric acid 25% 20 A C B B A C C C 80 A C B B A C C C 150 A C C B A C C C
Oxygen (Gas) 20 A A A A A A A A 50 A A A A A A A A
Oxygen liquid -200 A A A A A A C C 0 A A A A A A B C 20 A A A A A A A C
O-Xylol § 1,2 Dimethylbenzene 20 U A A A A C C C 80 U A A A A C C C
Palm oil § Vegetable oil 20 A A A A A A C A 80 A A A A A B C C 100 A A A A A C C C
Phosgene § Chloride of carbonyl 20 A A A C B A A B 80 A A A C C C B C
Phosphoric acid <10% aerated 20 A A A A A A A A 80 A A A A A B B B 100 A A B A A C C C
Phosphoric acid <10% Air free 20 U A A A A A A A 80 U A A A A B C C 120 U A A B A C C C
Phosphoric acid 80% 20 A A A A A A A C 80 A A A C A C C C
Potassium chloride 10% § Sylvine 10% 20 A A A A A A A A 80 U A A A A B A C 100 U A A A A C B C
Potassium cyanide 10% 20 A A B B A C A A 80 A A B B A C B C 100 A A B B A C C C
Potassium hydroxide 2% § Caustic potash 2% 20 A A B B A B A B 80 A A B B A C B C 120 A A B C B C C C
Potassium hydroxide 10% § Caustic potash 10% 20 A A B B A B A B 80 A A B B A C B C 120 A B B C B C C C
Potassium hydroxide 20% § Caustic potash 20% 20 A A B B A B A C 80 A A B B A C B C 120 A C B C B C C C
Potassium hydroxide 35% § Caustic potash 35% 20 A A B B A C A C 80 A A B B A C B C 120 A B B C B C C C
Potassium hydroxide 50% § Caustic potash 50% 20 A A B B A C A C 80 A A B C A C B C 120 A C B C B C C C
Potassium nitrate 25% 20 B A B B A A A A 80 U A B B A A A C 100 U A B B A C C C
Potassium nitrate 50% 20 U A B B A A A A 80 U A B B A U A C 100 U A B B A U B C
Potassium permanganate <20% 20 A A B B A C B C 80 A A B B A C B C 120 B B C C A C C C
Potassium sulfate 10% 20 A A A A A A A A 80 A A A A A B B C 120 U U B B B C C C
Propane (Gas) 0 A A A A A A C B 20 A A A A A A C B 50 A A A A A A C B
Propane liquid 0 A A A A A A C B 20 A A A A A A C B 50 A A A A A A C B
Propene § Propylene 20 U U A A A C C C 80 U U A B A C C C 120 U U B C B C C C
Propionic acid 50% 20 A A A C A A A C 80 A A A C B C B C
Silane 6.9 - 70% 20 U U U U U U U U
Silane M1 8 - 20% 20 U U U U U U U U
Silane M2 4 - 9% 20 U U U U U U U U
Silane M3 2 - 6.4% 20 U U U U U U U U
Silane MH6 6 - 55% 20 U U U U U U U U
Sodium bicarbonate 10% 20 A A B A A A A A 80 U A B A A C A C 120 U A C B A C C C
Sodium bisulfite 10% 20 A A B C A A A A 80 A A B C A B A C 120 B B C C B C B C
Sodium carbonate 20% 20 A A A A A A A B 80 A A A A A B A C 120 A A B B A C C C
Sodium carbonate 50% 20 A A A A A A A B 80 A A A A A B A C 120 A A B B A C C C
Sodium chlorate 5% 20 A A A B A A A B 80 A A A B A A C C 120 A A A C B B C C
Sodium chlorate 40% 20 A A A B A A A B 80 A A A B A A C C 120 A A A C B B C C
Sodium hydroxide 2% § Caustic Soda 2% 20 A C B A A A A B 80 A C C A A C C C 120 U C C B A C C C
Sodium hydroxide 5% § Caustic Soda 5% 20 A C B A A A A B 100 A C C A A C C C
Sodium hydroxide 10% § Caustic Soda 10% 20 A C A A A A A C 80 A C U A A A A C 100 U C U C A C C
Sodium hydroxide 20% § Caustic Soda 20% 20 A C B A A A A B 100 A C C A A C C C
Sodium hydroxide 30% § Caustic Soda 30% 20 A C B B A A A B 100 A C C C A C C C
Sodium hydroxide 35% § Caustic Soda 35% 20 A C A B A A A B 80 A C B C A C C C 120 U C C C A C C C
Sodium hypochlorite 15% 15 A A A C A B B C 80 A A C C A C C C 150 U A C C B C C C
Sodium nitrate 50% § Cubic nitre of salp. 50% 20 A A B A A A A B 80 A A C A A A A C 100 U A C B A B C C
Sodium nitrite 30% 20 A A B A A A A C 80 A A C A A A B C 100 A A C B A B C C
Sodium peroxide 10% 20 A C B A A B A C 80 A C B A A C B C 120 U C C B A C C C
Steam, saturated 80 A A A A A A A A 150 A A A A A A A A 500 U U U A C C C C
Steam, superheated 250 A A A A B C B C 500 U U U A C C C C
Stearic acid 27% 20 A A A A A B A B 80 A A A A A B A C 120 A A B A B C C C
Sugar liquid 10% 20 A A A A A A A C 80 A A A A A B A C
Sugar liquid 20% 20 A A A A A A A C 80 A A A A A B A C
Sugar liquid 30% 20 A A A B A A A C 80 A A A B A B A C
Sulfonic acid § Benzensulfonic acid 20 U U U U A C C U 80 U U U U U C C U 120 U U U U U C C U
Sulfur 20 A A B A A A A C 80 A A B A A C C C 150 A A B B A C C C
Sulfuric acid 0.5% 20 A A A A A A A C 80 A A C C A B B C 120 A A C C A C C C
Sulfuric acid 10% 20 A A A C A A A C 50 A A C C A B C C 80 A A C C A C C C
Sulfuric acid 20% 20 A A A A A A A C 80 A A C C A B B C 120 A A C C A C C C
Sulfuric acid 30% 20 A A A C A A A C 80 A A C C A B B C
Sulfuric acid 40% 20 A A A C A A B C 80 A A C C A B C C 120 B A C C A C C C
Sulfuric acid 90% 20 A A C A A A C C 80 A A C C A C C C 150 A A C C A C C C
Syrup Glucose R43 20 A A A A A A A C 50 A A A A A A A C 120 A A A A C C C C
 Chemical Name Temp 1 Platinum Tantalum Hastalloy SS316L PFA Hard Rub Soft Rubb PU Temp 2 Platinum Tantalum Hastalloy SS316L PFA Hard Rub Soft Rubb PU Temp 3 Platinum Tantalum Hastalloy SS316L PFA Hard Rub Soft Rubb PU
Tannic acid 10% § Tannin 10% 20 A A B A A A A A 80 A A B A A B A C 120 U U C B C C C C
Tannic acid 50% § Tannin 50% 20 A A B A A A A A 80 A A B A A A B C 120 U B C B B U C C
Toluene § Methylbenzene 20 A A A A A C C C 100 A A A A A C C C
Uric acid § Urea 20 U A B B A A A U 80 U A B C A U U U 100 U A B C B U U U
Waste water, City § Effluent § Sewage 20 A A A A A A A A 40 A A A A A A B B
Water (towns) 20 A A A A A A A A 80 A A A A A A A A 120 A A A A A C A C
Water (de-ionized) 20 A A A A A A A A 80 A A A A A A A A
Water, pure 20 A A A A A A A A 80 A A A A A A A A 120 A A A A A C A C

117
Magnetic Flowmeter
Conductivities of Selected Liquids

Magnetic flowmeters can measure a wide variety of liquids accurately if the liquid is conductive. The following
tables give conductivities of many of the chemicals which will be encountered and will allow you to quickly
determine if a magnetic flowmeter is applicable. Consult the factory for chemicals which are not listed. Also,
please verify the conductivity before use.

Liquid % By Micromhos/CM Liquid % By Micromhos/CM

Weight Weight
>20 >20<5 <5 >20 >20<5 <5
Acetaldehyde 100 � Ammonium bifluoride 50 �
Acetamide � Ammonium bisulfate 50 �
Acetic acid 0.3 � Ammonium carabamate 50 �
1 �
5 Ammonium chloride 5 �
�
10 10 �
�
20 15 �
�
30 20 �
�
40 25 �
�
50 � Ammonium fluoride 50 �
60 �
70 � Ammonium hydroxide �
99.7 �
Ammonium iodide 10 �
Acetic anhydride � 20 �
50 �
Acetone �
Ammonium nitrate 5 �
Acetophenone � 10 �
Acetronitrile 30 �
�
50 �
Acetyl bromide �
Ammonium persulfate �
Acetyl chloride �
Ammonium phosphate �
Acintol P �
Ammonium sulfate 5 �
Actol 31-56 triol � 10 �
20 �
Adipic acid � 30 �
Alizarin � 31 �

Allyl alcohol � Aniline �

Alphonic � Anthracene �

Alumina hydrate solution � Arsenic tribromide �

Aluminum chloride 80 � Arsenic trichloride �

Aluminum fluoride � Asphalt emulsion �

Aluminum nitrate � Barium chloride 5 �

10 �
Aluminum potassium � 15 �
sulfate 24 �
Aluminum sulfate 50 � Barium hydroxide 50 �
Ammonia 0.10 � Barium nitrate 4.2 �
0.40 � 8.4 �
0.80 �
1.60 � Barium sulfate �
4.01 � Benzadehyde �
8.03 �
16.15 � Benzene �
30.5 �
Benzoic acid �
Ammonium bicarbonate 50 �

118
 Liquid % By Micromhos/CM Liquid % By Micromhos/CM
Weight Weight
>20 >20<5 <5 >20 >20<5 <5
Benzonitrile � Cadmium sulfate 0.0289 �
0.0999 �
Benzyl alcohol � 0.495 �
Benzyl benzoate � 1 �
5 �
Benzylamine � 10 �
25 �
Black liquor �
36 �
Boric acid 50 �
Calcium bisulfite �
Brine �
Calcium bromide �
Bromine �
Calcium carbonate �
Bromobenzene �
Calcium chlorate 30 �
Bromoform �
Calcium chloride 5 �
Butryic acid 1 � 10 �
5.02 � 20 �
10.07 � 25 �
15.03 � 30 �
20.01 � 35 �
50.04 � 90 �
70.01 �
Calcium hydroxide �
100 �
Calcium hypochlorite 6 �
Cadmium bromide 0.0324 �
0.0748 � Calcium iodide �
0.154 �
0.506 � Calcium nitrate 6.25 �
1 � 12.5 �
5 � 25 �
10 � 37.5 �
20 � 50 �
30 � Calcium sulfate �
Cadmium chloride 0.0503 � Cane sugar juice �
0.2 �
0.599 � Capronitrile �
1 �
5 Carbamate �
�
10 � Carbon disulfide �
15 �
20 � Carbon slurry �
30 � Carbon tetrachloride �
40 �
50 � Carbonic acid �
Cadmium iodide 1 � Carboxylic acid �
5 �
10 � Caustic soda 50 �
15 � Chemonite �
20 �
30 � Chlorinated ether �
40 �
Chlorinated water �
45 �
Chlorine �
Cadmium nitrate 1 �
5 � Chlorine dioxide 15 �
10 �
20 � Chloroacetic acid �
30 � Chlorohydrin �
40 �
48 � Chocolate liquor �
Chromic acid All �
Cider �
Citric acid 50 �
Clay slurry �

119
 Liquid % By Micromhos/CM Liquid % By Micromhos/CM
Weight Weight
>20 >20<5 <5 >20 >20<5 <5
Coca-Cola® � Ethylene chloride �
Coffee extract � Ethylidene chloride �
Copper chloride 5 � Eugenol �
10 �
15 Ferric chloride 50 �
�
20 � Ferric nitrate 10 �
25 �
35 � Ferric sulfate 10 �

Copper ore slurry � Ferrous chloride 10 �

Copper sulfate 2.5 � Ferrous sulfate 50 �

5 � Fluosilicic acid �
10 �
15 � Formaldehyde 35 �
17.5 �
Formamide �
Corn syrup �
Formic acid All �
Cranberries, crushed �
Fruit juices �
Cream cheese mix �
Fudge �
Cupric chloride 1.35 �
9 � Furfural �
18.2 � Gallium �
28.75 �
35.2 � Germanium tetrabromide �
Cupric nitrate 50 � Gin, 90 proof �
Cupric sulfate � Glucose �
Cyanogen � Glutamic acid �
Cymene � Glycerol �
Dichloroacetic acid � Glycol �
Dichlorohydrin � Green liquor �
Diethyl carbonate � Guaiacol �
Diethyl oxalate � Heptane �
Dietyl sulfate � Hydrobromic acid 5 �
10 �
Diethylamine � 15 �
Dimethyl sulfate � Hydrochloric acid All �
Diofan 190(D) 55 � Hydrocyanic acid �
Epichlorohydrin � Hydrofluoric acid 0.004 �
Ethyl acetate � 0.007 �
0.015 �
Ethyl acetoacetate � 0.030 �
0.060 �
Ethyl alcohol 100 � 0.121 �
Ethyl benzoate � 0.242 �
0.484 �
Ethyl bromide � 1.5 �
Ethyl ether 2.48 �
�
4.80 �
Ethyl iodide � 7.75 �
15.85 �
Ethyl isothiocyanate � 24.5 �
Ethyl nitrate � 29.8 �
48 �
Ethyl thiocyanate �
Hydrogen bromide �
Ethylamine �
Hydrogen chloride �
Ethylene bromide �
Hydrogen cyanide �

120
 Liquid % By Micromhos/CM Liquid % By Micromhos/CM
Weight Weight
>20 >20<5 <5 >20 >20<5 <5
Hydrogen iodide � Magnesium chloride 5 �
10 �
Hydrogen peroxide 90 � 20 �
Hydroiodic acid 5 � 30 �
34 �
Hypochlorous acid (80°F) �
Magnesium nitrate 5 �
Ink � 10 �
17 �
Iodic acid �
Magnesium sulfate 5 �
Iodine �
10 �
Isophthalic polyester resin � 15 �
25 �
Isobutyl alcohol �
Manganese chloride 5 �
Isoproponol � 10 �
Isopropyl alcohol � 15 �
20 �
Iso-Valeric acid � 25 �
28 �
Kerosene �
M-Creosol �
Lactan �
Mercury �
Lactic acid 10-85 �
Mercuric bromide 0.223 �
Lard � 0.4202 �
Latex � Mercuric chloride 0.229 �
Latex paint � 1.013 �
5.08 �
Lead nitrate 5 � 60 �
10 �
15 � Methyl acetate �
20 � Methyl alcohol �
25 �
30 � Methyl ethyl ketone �
60 �
Methyl iodide �
Lime (calcium hydroxide) �
Methyl isobutyl ketone �
Lithium carbonate 0.20 �
0.63 � Methyl nitrate �

Lithium chloride 2.5 � Methyl thiocyanate �

5 � Milk (skim and regular) �
10 �
20 � Molasses �
30 �
M-Propyl alcohol �
40 �
M-Propyl bromide �
Lithium hydroxide 1.25 �
2.5 � Naphthalene �
5.0 �
7.5 � Nickel chloride 20 �

Lithium iodide 5 � Nickel nitrate 10 �

10 � Nickel sulfate �
20 �
25 � Nitric acid All �
Lithium sulfate 5 � Nitrobenzene �
10 �
Nitromethane �
Maleic acid �
Nonane �
Malic acid �
Oleic acid �
Magnesium carbonate 10 �
Oleum �
O-OR M-Nitrotoluene �
O-Toluidine �

121
 Liquid % By Micromhos/CM Liquid % By Micromhos/CM
Weight Weight
>20 >20<5 <5 >20 >20<5 <5
Oxalic acid All � Potassium fluoride 5 �
10 �
Paint, enamel � 20 �
Paper pulp � 30 �
40 �
Peanut butter �
Potassium hydroxide 4.2 �
Pentane � 8.4 �
16.8 �
Petroleum � 25.2 �
Phenetole � 33.6 �
42 �
Phenol � 50 �
Phenyl isothiocyanate � Potassium hypochlorite 40 �
Phosgene � Potassium iodide 5 �
Phosphate slurry 10 �
�
20 �
Phosphoric acid 10 � 30 �
20 � 40 �
30 � 55 �
35 �
50 Potassium nitrate 5 �
�
70 10 �
�
80 15 �
�
85 20 �
�
87 22 �
�
80 �
Phosphorus �
Potassium oxalate 5 �
Phosphorus oxychloride � 10 �
Photographic emulsion � Potassium permanganate 10 �
Pinene � Potassium persulfate 10 �
Piperidine � Potassium sulfate 5 �
10 �
Polystyrene � 20 �
Potassium 5-50 � Potassium sulfide 3.18 �
Potassium acetate 4.67 � 4.98 �
9.33 � 9.93 �
28 � 10 �
46.67 � 19.96 �
65.33 � 29.97 �
38.08 �
Potassium alum. sulfate � 47.26 �
Potassium bicarbonate 30 � Proprionaldehyde �
Potassium bisulphate � Proprionitrile �
Potassium bromide 5 � Propylene glycel �
10 �
20 � P-Toluidine �
30 � Pyresote �
36 �
Pyridine �
Potassium carbonate 5 �
10 � Quinoline �
20 �
30 Rosin size �
�
40 � Salicylic acid �
50 �
Salicylaldehyde �
Potassium chlorate �
Sewage �
Potassium cyanide 3.25 �
6.5 � Silver nitrate All �

Potassium dichromate 60 � Sludge, activated �

122
 Liquid % By Micromhos/CM Liquid % By Micromhos/CM
Weight Weight
>20 >20<5 <5 >20 >20<5 <5
Sludge, primary � Sodium sulfide 2.02 �
5.03 �
Soap � 9.64 �
Sodium acetate 5 � 14.02 �
20 � 16.12 �
32 � 18.15 �
40 �
Sodium aluminate �
Sodium sulfite �
Sodium bicarbonate 20 �
Soybean oil �
Sodium bisulfate 40 �
Starch �
Sodium bisulfite 40 �
Stearic acid 100 �
Sodium borate �
Strontium chloride 5 �
Sodium carbonate 5 � 10 �
10 � 15 �
15 � 22 �
Sodium chlorate 40 � Strontium nitrate 5 �
10 �
Sodium chloride 5 �
15 �
10 �
20 �
15 �
25 �
20 �
35 �
25 �
26 � Sugar solution Pure �
30 �
Sugar solution, dilute �
Sodium chromate �
Sulfonyl chloride �
Sodium cyanide �
Sulfur �
Sodium hydroxide 1 �
2 � Sulfur dioxide �
4 � Sulfuric acid 5 �
6 � 10 �
8 � 15 �
10 � 20 �
15 � 25 �
20 � 30 �
25 � 35 �
27.5 � 40 �
30 � 50 �
32.5 � 60 �
35 � 65 �
37.5 � 70 �
40 � 75 �
45 � 80 �
50 � 85 �
Sodium hypochlorite 20 � 86 �
87 �
Sodium iodide 5 � 88 �
10 � 89 �
20 � 90 �
40 � 91 �
92 �
Sodium nitrate All �
93 �
Sodium phosphate � 94 �
95 �
Sodium phosphate, � 96 �
tri-basic 97 �
Sodium silicate 37 � 99.4 �
40 � Sulfurous acid �
46 �
Tannic acid �
Sodium sulfate 5 �
10 � Tartaric acid 50 �
15 �
30 �

123
 Liquid % By Micromhos/CM
Weight
>20 >20<5 <5
Titanium dioxide �
Toluene �
Toothpaste �
Trichloroacetic acid �
Trimethylamine �
Trisodium phosphate �
Turpentine �
Uranium sulfate extract �
Urea 50 �
66 �
Pure �
Vodka, 100 proof �
Water (distilled) �
Water (city) �
Water (rivers & streams) �
Water, mineral �
White liquor �
Xylene �
Zinc chloride All �
Zinc oxide �
Zinc sulphate 5 �
10 �
15 �
25 �
30 �

124
English to Metric System Conversion

1 2 3 To Convert Column 2
To Convert Into Multiply by back to Column 1
multiply by
acre-feet cubic meters 1233 8.11 x 10 -4
cubic feet (cu ft) (US) cubic centimeters 28.317 3.53 x 10 -5
cubic feet (cu ft) (US) cubic meters 0.0283 35.33
cubic feet (cu ft) (US) liters 28.32 0.035
cu ft/min cu cm/sec 472 0.0021
cu ft/min liters/sec 0.472 2.119
cu ft/sec liters/min 1699 5.886 x 10 -4
cubic inches (US) cubic meters 1.64 x 10 -5
61.024
cubic inches (US) liters 0.0164 61.024
cubic inches (US) milliliters (ml) 16.387 0.0610
feet (US) ____________ meters 0.3048 3.281
_____
feet (US) millimeters (mm) 304.8 3.28 x 10 -3
feet/min cm/sec 0.508 1.97
feet/min kilometers/hr 1.829 x 10 -2
54.68
feet/min meters/min 0.305 3.28
ft/sec2 km/hr/sec 1.0973 0.911
gallons (US) cu cm (ml) 3785 2.64 x 10 -4
gallons (US) liters 3.785 0.264
gallons/min liters/sec 0.063 15.87
US gal/min cu meters/hr 0.227 4.4
US gal/sq ft/min cu meters/hr/sq meters 2.45 0.408
grains (troy) grams 0.0648 15.432
grains (troy) milligrams (mg) 64.8 0.01543
grains/gal (US) grams/liter 0.0171 58.417
grains/gal (US) ppm 17.1 0.0584
inches (US) centimeters (cm) 2.54 0.3937
inches (US) millimeters (mm) 25.4 0.0394
miles (US) kilometers (km) 1.609 0.6215
miles (US) meters 1609 6.214 x 10 -4
miles/hr cm/sec 44.7 0.0224
miles/hr meters/min 26.82 0.0373
miles/min kilometers/hr 96.6 1.03 x 10 -2
ounces (avoirdupois) grams 28.35 0.0353
ounces (US fluid) ml 29.6 0.0338
ounces (US fluid) liters 0.0296 33.81
pounds (av) grams 453.6 0.0022
pounds (av)/sq in kgr/cm2 0.071 14.223

125
 1 2 3 To Convert Column 2
To Convert Into Multiply by back to Column 1
multiply by
pounds (av) kilograms 0.4536 2.205
pounds (av) grains 7000 14.2 x 10 -5
pounds/cu ft grams/l 16.02 0.0624
pounds/ft grams/cm 14.88 0.067
pounds/gal (US) grams/ml 0.12 8.345
pounds/gal (US) grams/liter 119.8 8.34 x 10 -3
quart (US liq) ml 946.4 0.001057
quart (US liq) liters 0.946 1.057
square feet (US) sq cm 929 1.08 x 10 -3
square feet (US) sq meters 0.0929 10.76
square inches (US) sq cm 6.452 0.155

126
Equivalents

Linear Measure Measure of Volume Velocity

1 micron 0.000001 meter 1 cu centimeter 0.061 cu in. 1 ft/sec 0.3048 m/sec
1 mm 0.03937 in. 1 cu inch 16.39 cu cm 1 m/sec 3.2808 ft/sec
1 mm 0.00328 ft. 1 cu decimeter 0.0353 cu ft.
1 centimeter 0.3937 in. 1 cu foot 28.317 cu decimeters
1 inch 2.54 centimeters 1 cu yard 0.7646 cu meters
1 inch 25.4 mm 1 stere 0.2759 cord Density
1 decimeter 3.937 in. 1 cord 3.264 steres 1 lb/cu in 27.68 gram/cu cm
1 decimeter 0.328 ft. 1 liter 0.908 qt dry 1 gr/cu cm 0.03613 lb/cu in.
1 foot 3.048 decimeters 1 liter 1.0567 qts liq 1 lb/cu ft 16.0184 kg/cu m
1 foot 30.48 cm 1 quart dry 1.101 liters 1 kg/cu m 0.06243 lb/cu ft
1 foot 304.8 mm 1 quart liquid 0.9463 liters
1 meter 39.37 in. 1 dekaliter 2.6417 gals
1 meter 1.0936 yds 1 dekaliter 1.135 pecks
1 yard 0.9144 meter 1 gallon 0.3785 dekaliter
1 dekameter 1.9884 rods 1 peck 0.881 dekaliter
1 rod 0.5029 dekameter 1 hectoliter 2.8375 bushels
1 kilometer 0.62137 mile 1 bushel 0.3524 hectoliter
1 mile 1.6093 kilometers

Square Measure Weights

1 sq centimeter 0.1550 sq in. 1 gram 0.03527 ounce
1 sq centimeter 0.00108 sq ft. 1 ounce 28.35 grams
1 sq inch 6.4516 sq centimeters 1 kilogram 2.2046 pounds
1 sq decimeter 0.1076 sq ft. 1 pound 0.4536 kilogram
1 sq ft. 929.03 sq cm 1 metric ton 0.98421 English ton
1 sq ft. 9.2903 sq dec. 1 English ton 1.016 metric ton
1 sq meter 1.196 sq yds 1 kg 2.205 pounds
1 sq yard 0.8361 sq meter 1 cu in. of water (60 °F) 0.073551 cu in. of mercury (32 °F)
1 acre 160 sq rods 1 cu in. of mercury (32 °F) 13.596 cu in. of water (60 °F)
1 sq rod 0.00625 acre 1 cu in. of mercury (32 °F) 0.4905 pounds
1 hectare 2.47 acres
1 acre 0.4047 hectare
1 sq kilometer 0.386 sq mile
1 sq mile 2.59 sq kilometers
Circumference 2 πr
of a circle
Circumference 2 πd
of a circle
Area of a circle πr2
Area of a circle πd2

127
128
SERVICES
Close to you...
Total Service
Endress+Hauser instrumentation brings a high level of measuring quality to your process. Our aim is to keep it
that way.

That’s why our Customer Service group exists. It’s not only there to help in emergency situations, it’s there to
provide Help Desk Services and to arrange spares and consumables when you need them.

It’s there to help with on-site Commissioning. Our Technical Engineers are trained to optimize the instrument’s
performance, allowing you to get the best from your process.

It’s there for field and factory Calibration

Services. Regular calibration ensures that
the measurement quality remains within
specifications year after year.

It’s there to help with Training. Your

maintenance personnel will benefit from
professional, up to date and ”hands on”
training, encompassing the use of specialized
software tools.

It’s there to provide on-site Inspection and

Maintenance Services. We provide tailor made
Maintenance Agreements which give you peace of mind. But much more is available from Endress+Hauser.
Have you considered the management of your entire installed instrument base? What about improving uptime
and process yields? We can help you to keep your installed base fully operational, accurate and young.

Endress+Hauser’s Customer Service is one of the most important groups within our large international
organization, dedicated to providing the service that you need both now and in the future. Our objective is to
provide total support for you and for your instruments and to keep your plant working seven days a week and 24
hours a day.

Consultation and Planning

Endress+Hauser industry engineers consult plant engineers and process planners to provide process solutions for
most industries.

Documentation
As well as offering technical brochures and operating manuals in many languages, Endress+Hauser offers
detailed industry brochures and technical literature. Endress+Hauser documentation is available on paper, on
CD-ROM and on the Internet.

Exhibitions
Endress+Hauser exhibitions are also an interactive sounding board for technical process improvements.
Endress+Hauser exhibitions all over the world offer a platform on which to exchange the newest developments
and recommendations on process improvement.

Certification
Instrument certification is available from all major agencies, for hazardous zones, hygienic applications, Dust Ex,
etc.

Tooling
Many tools such as selection guides for processes are available from Endress+Hauser.

129

USA
Endress+Hauser, Inc.
2350 Endress Place
Greenwood, IN 46143
Tel. 317-535-7138
Sales 888-ENDRESS
Service 800-642-8737
Fax 317-535-8498
inquiry@us.endress.com
www.us.endress.com
www.us.endress.com/e-direct
CP 001O/24/ae/06.04
AE/INDD 2.0
06.04/SCUSA
Canada Mexico
Endress+Hauser Canada Endress+Hauser
1075 Sutton Drive Paseo del Pedregal No. 610
Burlington, ON L7L 5Z8. Col. Jardines del Pedregal
Tel. 905-681-9292 01900, Mexico D.F.
800-668-3199 MEXICO
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