Tackling

Measurement
Challenges
of Extreme
Process Industry
Applications

1
Tackling Measurement
Challenges of Extreme
Process Industry
Applications
Specialized instruments and associated software combined
with other tools provide solutions for your toughest
applications. Here are suggestions for five common areas.

“If it were easy, everybody would be doing it.” People involved in extreme
activities have likely made a similar statement when discussing their choices. Some
participate in extreme sports for the thrill and challenge of pushing one’s limits.
Others face challenges as part of their jobs, such as first responders and military
personnel. Whatever the motivation, they take on tasks few of us could manage.

Process manufacturing has its extreme applications, and those who design for
these environments must find ways to monitor and safely contain all manner of
dangerous reactions and products. Consider a process where two feedstocks
come together, generating a powerful exothermic reaction. The equipment
must withstand what is, in effect, a continuous explosion capable of generating
enormous amounts of heat and pressure, while yielding products that may be
both highly corrosive and toxic.

These situations are well beyond the capabilities of garden-variety equipment,

including instrumentation. And yet the need for accurate and reliable
measurements is more important than ever to control those critical processes
and avoid serious safety incidents. If the continuous explosion can’t be monitored
effectively, it could break out of its constraints, causing serious damage.

2
Extreme applications take many forms—some potentially violent, flammable, and
toxic, while others have more subtle hazards—but they still have the potential to
damage or shorten the service life of conventional process instruments. In this
eBook, we will examine five types of challenging conditions:

Vibration

Challenging Flows

Demanding Process Fluids

Extreme Temperatures

Severe Pressures

Each of these conditions are common to a variety of industries, including but not
limited to:

• Oil and gas (well sites, refining, liquified natural gas, etc.)
• Chemical processing (petrochem, fine chemicals, etc.)
• Power generation
• Pulp and paper

For each condition, we will consider what makes the process extreme, and then
look at the pressure and temperature instruments and associated tools Emerson
has developed to tame them. In some cases, these involve specialized materials,
physical design modifications, sensor signal processing, and even software able
to help make selection easier and more certain.

Take a look at each section and see how

Emerson can help you solve your most
challenging extreme applications.

3
1 VIBRATION
4
 I
n a typical process manufacturing facility, there are few situations where
vibration is desirable. In fact, there may be no situations. Vibration may
seem, at first glance, to fall at the low end of the extreme scale, but its
potential for damage should not be underestimated.
Gauge (Figure 1.2) uses a sophisticated sensor with transmitter electronics to
provide the capabilities of a full electronic transmitter, but in an analog gauge
form factor with a traditional needle display.

Outside of specialized applications such as vibratory conveyors, maintenance

teams go to great lengths to ensure equipment does not vibrate. Monitoring
is critical, because with rotating equipment, such as motors and pumps,
excessive vibration indicates misalignment, failing bearings, or other
problems. If vibrations are transferred from a pump to adjacent piping, it can
cause fittings and flange bolts to work loose, creating leaks.

VIBRATION VERSUS MECHANICAL INSTRUMENTS

Such vibration is tough on mechanical instruments, especially pressure
gauges, which operate using a delicate mechanism with springs and gears,
making them vulnerable to shock and damage (Figure 1.1). Where pressure
Figure 1.2: The Rosemount Wireless Pressure Gauge does the same job as the
pulsates or pipes vibrate, the needle may never sit still, wearing gears and mechanical version, and much more.
causing metal fatigue for the bourdon tube.
A small stepper motor moves the needle in real time. Add basic diagnostic
functions and WirelessHART® communication, and it checks the most-wanted
feature boxes, without the problems of traditional pressure gauges.

FLUID INDUCED VIBRATION

In a process unit, vibrations can be created by flowing fluids if the piping
configuration causes wake shedding and peculiar eddy currents. This situation
is very common where a thermowell is inserted into the fluid stream,
perpendicular to the flow, to provide a temperature reading.

In such a position, vortices form on both sides of the thermowell and create
high- and low-pressure areas capable of inducing vibration (Figure 1.3).
VIBRATION

Figure 1.1: Mechanical gauges have delicate internal mechanisms which are easy to
damage.

Most operators have seen typical results of vibration: leaking bourdon tubes,
bent indicator needles, or needles pointing randomly from broken gearing.
Some models are designed to withstand environments where pipes vibrate
or where moving equipment may cause impacts. Cases can be armored with
rubber covers and use beefed-up mechanisms, but these options add cost and
have limited effectiveness.

Many users like the functionality of a traditional pressure gauge, but not its
finicky mechanism and instability. Emerson’s Rosemount™ Wireless Pressure Figure 1.3: Liquid flow around a thermowell can create vibrations sufficient to cause
fatigue induced failure.

5
 Sometimes this vortex-induced vibration (VIV) is tolerable, but in other This leaves designers trying to determine how thin and long a thermowell
instances it acts as if hammers positioned on opposite sides are alternately can be in an application and still withstand the VIV. Like most things related
tapping on the thermowell. This can lead to two problems: sensor wiring to vibration, the answers are complex because there are few clear linear
failure causing a lost reading, or fatigue-induced failure of the thermowell relationships. For example, for a given thermowell installed in a given pipe,
itself. In this situation, the thermowell eventually bends or cracks which can vibration will change with fluid velocity but the two do not have a linear
lead to process containment loss. correlation. A certain fluid velocity will cause the VIV frequency to match
the natural frequency of the thermowell, which can cause the amplitude to
WIRE FATIGUE AND BREAKAGE increase significantly (Figure 1.5), with accelerated metal fatigue as the result.
If vibration can’t be eliminated, one mitigation technique is using redundant
sensors. Emerson’s Rosemount 3144P and 644 Temperature Transmitters
(Figure 1.4) can process signals from two sensors, either from separately
mounted sensors, or from dual sensors built into a single sheath. If the
measurements from the two sensors differ by an amount programmed into
the transmitter, an alert is triggered. Similarly, if one sensor fails, automated
Hot Backup™ functionality allows the transmitter to switch immediately from
the primary to the backup sensor without losing the reading.

Figure 1.4: One option in the Rosemount 3144P Temperature Transmitter family can Figure 1.5: When the frequency of the wake shedding matches the resonant frequency
process signals from two sensors to provide redundant measurements. of the thermowell, the resulting vibration can be violent.

These critical relationships can be analyzed mathematically using formulas

The greatest reduction in risk is achieved with two independent sensors,
outlined by ASME in its PTC 19.3 TW-2016 Standard. This calculation method
however this requires additional process intrusions. Two independent sensors,
has been built into Emerson’s Thermowell Design Accelerator (Figure 1.6).
even if they are feeding one transmitter, can reduce the probability of losing
It is a free online thermowell calculation tool that guides a design engineer
the reading by 80%.
VIBRATION

through the sizing process by analyzing the likelihood of vibration problems

THERMOWELL DURABILITY for a specific thermowell shape in a specific installation. Each calculation
When VIV is an issue, the conventional solution is simply using a massively involves about 20 variables for the dimensions and operating characteristics,
thick and/or very short thermowell which can stand up to the vibration. This is so it is difficult to process manually. It must also be repeated for each set of
a problem for several reasons: operating characteristics, another reason to use automated online software.

• A heavy cross section causes significant time lag for the sensor to respond
to changes in temperature.
• Large diameter thermowells can be difficult to mount and cause increased
internal pipe blockage.
• A short thermowell may not extend far enough into the process media
stream to deliver an accurate temperature reading.

6
 Figure 1.6: Thermowell Design Accelerator organizes complex design calculations.
The process data for the various operational levels can be entered manually
or uploaded using an Excel-based template that allows the designer upload
multiple thermowell tags all at once. If a specific variable is missing, say a
dimensional unit like nozzle height, the Thermowell Design Accelerator has an
option to fill in a value based on experience within the plant, or more general
industry data. It is labeled as an estimate so anyone reviewing the data will
understand it may be subject to correction.
Figure 1.7: The Rosemount Twisted Square Thermowell breaks up wake-shedding
effects, reducing vibration by up to 90%.
Helical geometries like this have been used successfully with wind stacks
and deep-sea risers to solve similar problems. This type of thermowell does
not depend on a specific orientation when inserted, reducing the need for
excessively thick thermowells and large-diameter process penetrations. l

This system performs calculations in the usual way, but also permits users to
test what-if scenarios to see if a thinner thermowell might work, or if a stock
size already in use in the plant can do the job without adding another new part
number to the list. These alternatives are offered as possibilities, providing
designers with the flexibility to make the final call.

AVOIDING FLUID-INDUCED VIBRATION

Suppressing vibration at its source generally involves using a thermowell
profile designed to avoid normal wake-shedding problems. Some engineers
try to do this by substituting modified cylindrical, stepped, and tapered
VIBRATION

thermowells, but these are all basically round, allowing vortices to form
along the entire length. Emerson’s patented Rosemount Twisted Square™
Thermowell (Figure 1.7) disrupts formation of these long vortices and allows
them to form on both sides, so they tend to balance and cancel each other. The
result is far less vibration, up to a 90% reduction in some cases.

7
 ON
T I
A

R B
VI
T:
Reduce thermowell failure due to vortex-

HIGHLIGH
induced vibration
With its unique design and ability to handle applications with
changing process conditions, Emerson’s Rosemount Twisted
Square Thermowell eliminates over 90% of dynamic stress and
greatly reduces vortex-induced vibrations, the leading cause of
thermowell failure.

Watch How it Works

8
2 CHALLENGING
FLOWS
9
 A
pplications can become extreme based on fluid flow characteristics.
We’ll consider three areas that pose particular challenges for
instrumentation:

• High-velocity flows
• Wide flow-turndown range
• Large line sizes

HIGH VELOCITY
The traditional wisdom in years past was that liquid flow in pipes should be less
than 7 feet per second (FPS) to avoid excessive pressure loss, pipe wear, and
high pumping costs. More recently, some engineers figured out the cost of
having pipe large enough to support such moderate flow velocity was greater
than the consequences of higher velocities. Flow rates were increased, and/
or smaller pipes were used to save initial costs. Flow velocities are now higher,
Figure 2.1: The Rosemount 585 Annubar offers capabilities for severe service and high
sometimes a lot higher, with varying long-term effects. Let’s look at the
temperatures.
CHALLENGING FLOWS
different ways velocity-related problems can be avoided, or at least mitigated.
When measuring temperature, inserting a thermowell into a pipe with high
When measuring flow, high-velocity fluids pose additional challenges. First,
velocity flow can realize many of the problems related to VIV mentioned in
it is important to minimize the pressure drop across the primary element.
the previous section. While it is difficult to predict in every situation, high
Second, velocity gradients within the pipe can be more severe, so it is
velocities can make wake shedding action more violent, and if the frequencies
important to take an averaging reading across the full cross section to ensure
encountered approach the natural frequency of the thermowell, damage can
an accurate measurement. This is especially important for large line sizes.
be realized very quickly.
One way to solve both of these problems is to use Emerson’s Rosemount 585
The need for a thermowell design that avoids vortex formation is all the more
Annubar™ Primary Element for Severe Service (Figure 2.1). This averaging pitot
important, so Emerson’s Twisted Square Thermowell design should be first on
tube sensor is minimally intrusive in the pipe, is symmetrical for bi-directional
the list of potential solutions.
flow, and self-averages velocity gradients for high accuracy. It is suitable for
liquid, gas, and steam with velocities up to 300 FPS. It determines volumetric WIDELY VARIABLE FLOW RANGE
flow, which can be combined with a temperature measurement and known Most process units are designed to operate within a relatively narrow
fluid density characteristics, to calculate mass flow as well. production range. This makes life easier for instrumentation engineers since
they can size instruments to fall in the measuring sweet spot during normal
operation, but applications where the flow range can be wider creates greater
challenges.

Some flow meters, such as Emerson’s Micro Motion™ Coriolis designs, have
a wide turndown range, but these sophisticated models are often overkill
for general applications. When more conventional DP flow measurement
techniques are used, some users resort to an outdated practice of double-
stacking two DP transmitters with different measuring ranges on the same
primary element. This works but is very cumbersome for installation and signal
processing.

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 Emerson has developed Ultra for Flow in combination with its Rosemount
3051S Coplanar™ Pressure Transmitter (Figure 2.2), extending the measuring
range to keep the percentage error range far more uniform, even when the
DP value falls below its normal range. This avoids the problem of reduced
accuracy at the low end of the range due to percentage-of-span accuracy
characteristics.

Low flow Normal “% of Reading”

pressure flow pressure pressure transmitter
transmitter transmitter

Figure 2.3: The Annubar profile can be made in long lengths to span large line sizes.

Temperature measurements have different complications. Large line sizes call

CHALLENGING FLOWS

Figure 2.2: Ultra for Flow changes the error characteristics of a Rosemount 3051S
Coplanar Pressure Transmitter so it is more accurate over a wide turn-down range.
Wide flow-turndown also affects thermowells for temperature measurement
since there is a much greater potential for the wake shedding frequency to
match the resonant frequency of the thermowell. This emphasizes the value of
a vibration-resistant design such as Emerson’s Twisted Square Thermowell.
For a designer analyzing the likely vibration characteristics that the
application will create, it will be necessary to run a much longer list of
thermowell calculations since there are so many potential flow rate points.
This emphasizes the need for software like Emerson’s Thermowell Design
Accelerator to make calculations far more quickly to review all the possibilities.
for long thermowells able to reach to the pipe center, but these are especially
vulnerable to VIV. Again, using Emerson’s Twisted Square Thermowell and
Thermowell Design Accelerator makes these difficult applications far easier to
implement.
HELP WITH DP FLOW METER SELECTION
DP flow meters can use a wide variety of primary elements, including Annubar
averaging pitot tubes, depending on the application. An instrumentation
engineer trying to make the best selection can use new online software
tools to simplify the specifications and ensure the best choice. Emerson’s DP
Flow Sizing and Selection Tool (Figure 2.4) serves as an advisor, streamlining
product sizing and configuration by generating flow calculations faster and
with higher accuracy.

LARGE LINE SIZES

While the types of instruments discussed so far are highly scalable, creating
versions for large pipe and duct sizes used for buried water lines, stacks, and
air handlers, can get expensive. Emerson’s Rosemount Annubar Technology
(Figure 2.3) is very well suited to large line sizes since the Annubar sensor can
be built to virtually any length up to 25 feet. This reduces cost, even for cross-
sections up to 96 inches and above.

Fig 2.4: Emerson’s DP Flow Sizing and Selection Tool guides users through the
configuration process.

11
 Once the initial operating scope parameters are settled and the specific
application is identified (instrument location, tag number, etc.), a flow meter
or primary element selection must begin with a detailed understanding of the
application conditions, which is where the advisor initiates a detailed question-
and-answer process covering the application.

• What is the piping (size, material, orientation, etc.) in the area of installa-
tion?
• What is flowing through the pipe?
• Describe the normal operating conditions, plus minimum, maximum, and
full-scale readings for flow rate, pressure, temperature, etc.

These determine what the flow meter will see in normal service, as well as
during various common procedures (startup, shutdown, grade change, etc.).
Once these variables have been characterized, more subjective elements come
into play.
CHALLENGING FLOWS

• What degree of accuracy and turn-down range is expected?

• How much pressure loss can be tolerated?
• How easy is it to install a given type of primary element?
• How much straight pipe run is available and practical to deliver accurate
readings?

The DP Flow Sizing and Selection Tool makes up for a lack of experience as
plants work to develop younger engineers. Its final presentation can include
a table of data illustrating the operating characteristics in the application
context. When the process is complete, the designer will receive a full
configuration description and part number based on vendor catalog data. All
that remains is requesting a formal quote or placing an order. l

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 G F LOWS
G IN
EN
L L

HA C
T:
Power company improves air flow

HIGHLIGH
measurement in large ducts
An end user needed a way to improve air flow to increase
combustion efficiency and reduce emissions. The plant had
been inferring secondary airflow from fan curves, but this was
very inaccurate. The rectangular duct measured 4-feet by 5-feet
with uneven distribution, making traditional measurement
technologies costly and difficult to implement. As a result, the
plant ran with excess air, wasting fuel and losing efficiency.
Emerson’s Rosemount Annubar primary element was introduced
as a cost-effective way to achieve accurate flow measurement.
Because the duct was large and rectangular, plant personnel
installed two primary elements in parallel to capture a larger
section of the flow profile. Once installed, field service personnel
verified a flow accuracy of ±5%, which resulted in an immediate
fuel saving of 10%.

Read Case Study

13
3 DEMANDING
PROCESS FLUIDS
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et’s turn our attention away from instrumentation and look at what is
flowing through the pipes, the process fluid itself. Usually this breaks
into three categories: liquid, gas, and steam. The characteristics that
make a fluid extreme in our context include some mix of:

• Abrasiveness, usually due to fine particulates

• Corrosiveness, highly acidic or caustic, or containing aggressive chemicals
such as chlorine

DEMANDING PROCESS FLUIDS Some products can be highly toxic, flammable, or environmentally dangerous,
but these characteristics don’t necessarily attack instruments and equipment,
although they increase the importance of maintaining containment. For our
discussion, we’ll concentrate on elements able to affect instruments and
equipment directly.
LOSS OF MATERIAL
The common denominator of the damage caused by these fluids is loss of
metal, either eaten away chemically, worn away by abrasiveness, or both
working in combination. Solutions call for materials that are chemically
inert relative to the fluid, and/or hard enough to withstand the constant
scraping action of the abrasive. In some cases, materials reach their limits,
and the solution calls for finding ways to live with a shorter service life for the
equipment.
Where corrosiveness is the primary problem, the solution is often to
manufacture all the wetted parts of the equipment in a specialized alloy
designed to withstand the service. A frequent selection is one of a large family
of stainless steels with high nickel, molybdenum, and chromium content for
corrosive service. Emerson routinely makes thermowells and other parts in
such materials as requested.
However, in some cases, the answer isn’t always so simple. Pressure
instruments are particularly vulnerable to attack, so this calls for a closer look.
Figure 3.1: A diaphragm seal keeps process fluid out of the impulse lines.
All diaphragm materials have their limits for protection against abrasive
fluids. The durability of these diaphragms can be increased with Emerson’s
AbrasionShield technology by coating them in a protective layer of hard-
carbon nanostructured material to withstand abrasive process fluids better.
The micro-thin coating does not impact remote seal accuracy or sensitivity.
Another limitation of diaphragm seals is the permeability of atomic hydrogen
if present in the process fluid. These hydrogen atoms can migrate through
the diaphragm and once in the fill fluid, unite to form molecular hydrogen.
Because molecular hydrogen is too large to permeate back through the
diaphragm, it gets trapped and forms hydrogen bubbles in the fill fluid. These
bubbles can severely affect transmitter performance. Adhering a thin layer
of gold to a base metal diaphragm provides protection against hydrogen
permeation.
The life of these diaphragms can be extended by coating them with an
additional material to increase chemical resistance, abrasion resistance,
or decrease permeability. These protective coatings are part of Emerson’s
SensorShield family of enhanced diaphragm coatings including AbrasionShield
and CorrosionShield (Figure 3.2) in addition to standard coating options.

With severe fluids, containment is very critical, so engineers often use remote
seals, such as Emerson’s Rosemount 1199 Diaphragm Seal System (Figure
3.1), to eliminate the possibility of the process fluid getting into impulse lines
or the pressure instrument itself. These thin diaphragms have unique flexing
characteristics to provide the necessary measuring sensitivity and accuracy.
Fortunately, diaphragms can be manufactured from a variety of materials,
including stainless steels, tantalum, and nickel-based alloys such as Alloy C-276
or Alloy 400.

15
DEMANDING PROCESS FLUIDS
Figure 3.2: Using a permeation-resistant additive, CorrosionShield technology slows
process fluid from penetrating the coating to enhance corrosion resistance and extend
the life of the diaphragm seal.
For example, plating a 316 stainless steel diaphragm with 5 microns of gold can
effectively eliminate hydrogen permeability. Similarly, abrasion-resistant hard-
carbon nanostructured coatings can be vapor deposited on the surface that
are capable of extending service life up to 10 times compared to a standard
316 stainless steel diaphragm in abrasive service.
AVOIDING WETTED PARTS
Where conditions make adding a conventional thermowell impractical, some
users measure process temperature by clamping a temperature sensor to
the outside of the pipe. This provides a reading, but heat dissipation from the
pipe’s surface keeps the external temperature from ever fully reaching the
internal value. Adding insulation can help, but the reading may never truly
reflect the interior, and changing external conditions will cause unpredictable
fluctuations.
Emerson’s Rosemount X-well™ Technology (Figure 3.3) solves this problem
by using a different methodology to create a truly comprehensive solution. It
corrects for heat loss using an algorithm to compensate for heat transmission
and external conditions. The user enters factors for the pipe material
and thickness, and the instrument does the rest providing a true process
temperature measurement that can be as accurate as a traditional installation
that uses an inserted sensor and thermowell.
Figure 3.3: Emerson’s Rosemount X-well Technology provides a highly accurate process
temperature reading through a pipe wall without a penetration.
When clamped on a pipe, a resistance temperature detector (RTD) is held
in contact with the pipe surface to assure predictable and consistent heat
transfer. Once insulated, the reading from the surface RTD is compared
to a second RTD in the transmitter electronics. These two readings are
continuously run through the algorithm to calculate the temperature inside
the pipe, even when ambient and other conditions change significantly. The
result is a highly accurate temperature reading without the need for a process
penetration.
DESIGNED FOR DURABILITY
Flammable or dangerous fluids require equipment designed with features
that ensure reliable and safe operation in these environments. Often this
calls for construction using “industrial strength” proportions able to take
the punishment, while allowing for changing out parts when necessary with
minimal disruption. Such is the thinking behind the Rosemount 9295 Process
Flow Meter (Figure 3.4).
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DEMANDING PROCESS FLUIDS

Figure 3.4: The Rosemount 9295 Process Flow Meter is built to withstand the most
severe environments.

This flow meter is built upon a fully welded spool section with built-in isolation
valves and temperature input. It comes fully assembled to the Rosemount
3051S Pressure Transmitter and is leak tested at the factory. It uses proven
Conditioning Orifice Technology to minimize the need for upstream and
downstream straight pipe run. The impulse lines are short, and the DP
transmitter is close-coupled to minimize the potential for plugging. The
impulse lines also have gate-type isolation valves and clean-out ports so they
can be rodded out while the unit is in operation, and the entire DP transmitter
can be removed and replaced without a process shutdown.

The assembly can include an integral temperature sensor which sends its
information to the main DP transmitter, which can report the value to the
automation host system. When the fluid temperature is combined with the DP
volumetric flow rate and a known fluid density, the transmitter can provide a
mass flow measurement.

The DP transmitter can also provide static line pressure values to enhance the
mass flow measurement without an additional pipe penetration. A setup such
as this can typically handle fluids up to 600 °F (315 °C) or higher, depending on
the application and installation. l

17
 ID S
F LU
SS
C E

O
PR
T:
Diaphragm failure identifies unrecognized

HIGHLIGH
process problem
A chemical plant was using a remote diaphragm seal in conjunction
with a pressure transmitter in conventional hydrocarbon service.
Since this was considered a simple cut-and-dried application, it used
conventional stainless steel materials for the equipment. So, there was
consternation within the reliability team when a brand-new diaphragm
seal began leaking after only a month in service.
Emerson’s technicians studied the failure and found evidence that
the diaphragm was attacked by chlorine. This proved puzzling since
there should not have been any chlorine in the process, however the
plant’s analysis showed there was indeed chlorine contamination in the
feedstock that had passed unnoticed.
Plant personnel replaced the diaphragm seal with a Rosemount 1199
Diaphragm Seal System made from Alloy C-276, and then began
examining other areas in the process piping to look for signs of
corrosion, since the potential for ongoing chlorine contamination could
not be ruled out.

Read Article

18
4 EXTREME
TEMPERATURES
19
 W
hen we think of difficult temperatures, hot normally comes
to mind, but cold also presents its own set of challenges,
particularly in cryogenic ranges. With both extremes, the
first step is protecting any electronics since circuit boards and
components have relatively limited operating ranges.
As for instrument configurations, many of the same techniques can be used
to protect from cold as well as hot temperatures, and are also used to protect
from aggressive fluids, although there are some specialized variations. Let’s
look at how these solutions work together.
LOW ENVIRONMENTAL TEMPERATURES
EXTREME TEMPERATURES
The cold end of the temperature range is doubly problematic because it can
reflect the process fluid, but also the environment. Some oil production areas
in Canada and Russia routinely experience winter temperatures of -40 °F (-40
°C), which can affect equipment as well as people (Figure 4.1).
Figure 4.1: Instrumentation still has to work, even when it’s cold outside.
Many electrical devices actually work better in mildly colder weather. The
electrical resistance of conductors goes down, and this relationship of
temperature and resistance makes sensing technologies such as RTDs and
thermistors possible. However, problems begin to develop when sophisticated
devices, such as the A/D converters and other elements of field device
transmitters, move out of a moderate range. Fortunately, Emerson’s electrical
designers have built better circuits, and the internal components have
improved so their characteristics are better understood, and their potentially
negative effects reduced.
Emerson’s Rosemount 3051 Coplanar Pressure Transmitter is designed to
operate at temperatures down to -40 °F (-40 °C), however in some cases, this
isn’t enough. It can be specified with a Cold Temperature Start-Up Option
which guarantees that it will start-up down to -76 °F (-60 °C). However, it may
not deliver full accuracy if the temperature remains below -40 °F (-40 °C).
As a practical matter, in these environments, more extreme measures are
often used, including liberal use of heat tracing and heated instrumentation
cabinets. Nonetheless, instruments are available to handle the most extreme
cold temperature ranges without the need for extra protection.
MEASURING CRYOGENIC TEMPERATURES
Conventional temperature sensors can often be used when switching to the
low end of the spectrum, however there are limitations. Whereas RTDs are
often a first choice for many normal applications, when moving into the world
below -58 °F (-50 °C), it is critical to know the sensor’s rating since they vary.
Different classes of RTDs have different low limits, ranging from -58 to -328 °F
(-50 to -200 °C).
Thermocouples (TCs) are better adapted to handling low temperatures,
provided an appropriate type is selected. Some, such as type B, simply aren’t
suitable for temperatures below 0 °C. Types E, K, N and T have ranges down to
-450 °F (-270 °C), with Type T especially popular for cryogenic applications.
Once below -150 °F (-100 °C), most TCs begin to lose linearity (Figure 4.2).
This is not a problem necessarily since it is a known characteristic and can be
corrected in the programming of Emerson’s various Rosemount Temperature
Transmitters.
20
EXTREME TEMPERATURES
Figure 4.2: Thermocouples are better than RTDs for low temperatures, but it is critical
to compensate for changes in linearity. Rosemount Temperature Transmitters can
perform corrections automatically.
However, not all temperature transmitters or controllers are set up to work at
the low end, so users must make sure any device used in these applications has
the required capabilities.
DP FLOW METERS FOR LOW TEMPERATURES
DP flow meters using a Rosemount 3051 Coplanar Pressure Transmitter can
be used with cryogenic liquids, such as liquified natural gas (LNG), but it is
important to pay particular attention to the placement of the various devices
and the material selection for the components.
For DP flow meters in conventional liquid applications, the typical mounting
position places the transmitter and impulse lines below the pipe to prevent air
and gas entrapment. LNG applications reverse this, positioning the transmitter
above the primary element (Figure 4.3) so there is an insulating gas barrier
preventing contact of the cold liquid directly with the transmitter diaphragm.
Brief direct contact will not cause the instrument to fail, but it will slow its
response to changes in flow.
Figure 4.3 DP flow meters can be used with LNG and other cryogenic liquids, but the
transmitter should be placed above the pipe.
The transmitter has a stainless steel body which can handle the cold, but
it is important to look at other parts, such as the impulse lines. Designers
must ensure gaskets, o-rings, and bolts are also compatible with these low
temperatures, as the wrong materials can become brittle at low temperatures
and lead to leakage. DP flow meters equipped with welded impulse lines
reduce the potential for sealing material embrittlement by moving gaskets
away from the frost line. Impulse tubing should be small diameter, typically
0.25 in. (6 mm), to help maintain the gas barrier.
ISOLATING THE TRANSMITTER
Treatment of high and low temperature applications use similar techniques as
handling aggressive fluids discussed previously. Emerson’s Rosemount 1199
Diaphragm Seal System can be used for pressure or level measurements.
Extreme temperatures at either end of the spectrum call for specialized fill
fluids designed to retain their fluidity at the operating temperature without
freezing or boiling. In cases where the length of the capillary lines allows the
fill fluid to come to ambient temperature, it can cause a blockage and slow
response or cut it off entirely.
21
 The Rosemount 3051S Thermal Range Expander (Figure 4.4) allows use of
two fill fluids, one optimized for the process temperature and the other for
the ambient temperature. The two can be tailored to the application and
environment, eliminating the need for heat tracing or other protection
methods.

EXTREME TEMPERATURES

Figure 4.4: The Thermal Range Expander uses two fill fluids, each one optimized
for process and ambient temperatures. It can be used in high or low temperature
applications.

With appropriate fill fluids, the Thermal Range Expander can be used for
temperatures up to 770 °F (410 °C) or down to -157 °F (-105 °C). l

22
 M P S
E
ET
EM
R

XT E
T:
Refinery improves vacuum tower level

HIGHLIGH
measurement
The operators of a plant’s cracker towers routinely struggled to contain
excessive upward vapor flow that impeded downward liquid flow, resulting in
liquid accumulation in the column and poor separation. Operators then had
to reduce vapor rates and reboiler duty, resulting in off-spec products.
The tower was equipped with nuclear technology level instruments, but these
were troublesome for a variety of reasons, and could not provide enough
accuracy to solve the operational problems. A DP level approach looked like
it could do the job, but it would require a cumbersome installation with heat
tracing for long impulse lines. Plus, the operating temperature of up to 770 °F
(410 °C) posed its own problems.
Emerson’s solution used two technologies: Rosemount 3051S Electronic
Remote Sensor (ERS)™ with a Thermal Range Expander. This provided a
mechanism to handle the operating temperature without the need for heat
tracing and eliminated the long impulse lines all together. UltraTherm 805
fill fluid provided the capabilities required for this high-temperature vacuum
application.

Read Case Study

23
5 SEVERE
PRESSURES
24
 L
ike temperatures, extreme pressures can be high or low, and both ends
of the spectrum present their unique challenges. A pressure gauge or
transmitter must be able to operate continuously and for potentially
years at a time within its expected operating range, but it should have
additional capacity to withstand pressure spikes. Countless mechanical gauges
have suffered damage in this way due to their delicate internal mechanisms.
A bourdon tube pushed past its limits won’t return to the correct shape or
may simply burst. Fortunately, electronic transmitters can have more robust
construction.
Figure 5.1: Three high-pressure options include, left to right, Rosemount Wireless
A well-designed transmitter can absorb a moderate spike and return to its Pressure Gauge, Rosemount 3051 In-Line Pressure Transmitter, and Rosemount 4600
normal operating capabilities as if nothing happened. A more severe spike may Pressure Transmitter.
knock it out of range but without a loss of containment. The worst situation is
where a spike causes a burst or leak requiring a process shutdown if it can’t be When a more conventional pressure transmitter is needed, the Rosemount
isolated. 3051 In-Line Pressure Transmitter can handle up to 20,000 psi (1,379 bar) gage
or absolute. Rosemount 3051 In-Line Pressure Transmitters are SIL2/3 certified
HIGH PRESSURE SOLUTIONS for use in the most safety critical applications. Additionally, they include basic
Most general process instrumentation providers top out at 20,000 psi (1,379 and advanced device diagnostic capabilities. The Loop Integrity diagnostic can
SEVERE PRESSURES

bar), since applications beyond this are rare and highly specialized. Figure 5.1
shows three types of instruments with ranges up to 20,000 psi (1,379 bar). The
pressure gauge may seem out of place in the group but it belongs because the
Rosemount Wireless Pressure Gauge does not have a conventional mechanical
mechanism. Instead, it uses industry-proven sensor technology which avoids
common traditional gauge failures. This pressure sensor provides up to 10
years of maintenance-free operation by replacing mechanical components,
while providing more reliable readings and a higher overpressure limit of up to
1.5 times its range.
monitor the electrical loop and detect changes that compromise the integrity
of the output signal.
For panel-mount applications, the Rosemount 4600 Pressure Transmitter
can also handle up to 20,000 psi (1,379 bar) gage or absolute. It features a
compact, lightweight design with all-welded, stainless steel construction,
providing a stable and robust solution for harsh environments.
TOUGH FLOW MEASUREMENT
Consider the challenge of measuring flow of a high-pressure line, say 5000 psi
(345 bar), using a DP transmitter and conventional primary element. There
will be a pressure drop across the primary element, but if the application is
engineered well, it should only be around 30 psi (2 bar) at normal operating
range. This presents a serious challenge for the transmitter to produce a
precise reading of a very small pressure differential in an environment where
the static pressure can easily be hundreds of times more than the differential.

This is exactly the scenario that Emerson’s Rosemount 3051S High Static DP
Transmitter (Figure 5.2) is designed to handle.

< • > 25 25
 Figure 5.2: When it is necessary to look for a small pressure differential in a high-
pressure application, the Rosemount 3051S High Static DP Transmitter is often the
first choice.
SEVERE PRESSURES

It has a DP range up to 150 psi (10.3 bar) but can withstand static line pressures Figure 5.3: Pressure and temperature figure into selection of a fill fluid in a high
vacuum application.
up to 15,000 psi (1,034 bar). Its construction resists overpressure and line
pressure effects to maintain 0.055% accuracy with 10-year stability, even in
When a Rosemount 3051S Pressure Transmitter and 1199 Diaphragm Seal
very harsh environments.
System is chosen for an application, all-welded seals should be specified to
WORKING IN A VACUUM avoid drawing air into the capillary system.
Low pressures are considered anything below atmospheric, 14.7 psi (1 bar).
THE RIGHT TOOLS
Measurements made in these conditions still use the same instruments
Any reasonable person participating in extreme activities, whether for
and associated equipment, including the Rosemount 1199 Diaphragm Seal
pleasure or work, will want to have the right protective equipment because it
System, but special consideration must be given to the fill fluid. When enough
is critical to success and even survival.
vacuum is applied to a liquid, it can reach its boiling point and vaporize. If this
happens to the fill fluid, it can cause the whole system to fail. These issues are Emerson’s products for extreme applications are designed to ensure
exacerbated when the ambient or process temperatures are high. reliable performance and safety in these most challenging applications.
The technologies and practices suggested are designed to improve
When the process is under vacuum conditions, the fill fluid will vaporize under
instrumentation performance, increase reliability, and reduce maintenance.
a lower temperature than when it is operating under normal atmospheric or
None of them represent major capital projects, nor do they have to be
greater pressure. Emerson offers numerous types of fill fluids for remote seal
executed on a grand scale. Each improvement can be implemented one-by-
systems, and each fill fluid has a specific vapor-pressure curve (Figure 5.3).
one to deliver incremental gains and a quick return on investment, eliminating
The vapor-pressure curve indicates the pressure and temperature relationship
obstacles to effectiveness and profitability.
where the fluid is in a liquid or vapor state. Proper seal operation requires the
fill fluid to remain in a liquid state. Keep in mind that these are only one part of the larger picture as there are
many other potential areas where Emerson can help process manufacturers
improve performance. l

< • > 2626

 SU R E S
R E S
E P
ER

EV S
T:
Oil and gas facility saves $290,000 in

HIGHLIGH
panel costs
An end user was looking for a solution to minimize the weight,
size, and overall cost of their control panels. They selected
Rosemount 4600 Pressure Transmitters because of their
compact package and best-in-class performance and stability.
The Rosemount 4600 features an integral conduit seal to allow
mounting directly into the bulkhead. This eliminates additional
conduit and conduit seals, as well as additional mounting brackets.
Because of the compact design of the Rosemount 4600
transmitter, this oil and gas facility was able to save $290,000
in panel costs. Additionally, many offshore platform projects
are under pressure to reduce the weight of the platform. The
Rosemount 4600 weighs 74% less than a conventional pressure
transmitter, which can reduce the overall weight of a panel by
30-50%.

Read Case Study

27
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