Present de Conductividad Bailey - ABB

Theory, Installation,
Calibration and
Cleaning of Industrial
Conductivity Loops
Jorgi M. Day, Ch.E.
© ABB Instrumentation
Carson City, Nv - 1 -
01-04-06 -
Significant Factors in Conductivity Monitoring
 Sensor Technology
 Installation
 Calibration
 Maintenance
Carson City, Nv. - 2
What Is Conductivity?
 Nonspecific measurement of a fluid comprised of dissolved solids,

salts, and other components. As concentrations increase, the
conductivity typically increases.
 Measure of water quality
 Is it clean?
 How clean is clean?
 Applications
 Water treatment
 Boilers
 Cooling towers
 CIP systems
 Leak Detection in a heat exchanger
 Pulp & Paper
 Phase change
Units of Operation
Resistance (ohm)  
1 1
Conductance (Siemen formerly mho)     1  S
ohm 
 Common Units
1 S  1,000 mS  1,000,000 S
Specific Conductivity (approx.)
Pure Water 0.055 uS/cm
Distilled Water 0.5 uS/cm
Boiler Feed Water 0.07 – 5 uS/cm
Tap Water 50 – 300 uS/cm
Ocean Water 50 mS/cm
10% NaOH 355 mS/cm
15% NaOH 410 mS/cm
19% HCl 850 mS/cm
5% NaCl 75 mS/cm
Concentration vs. Conductivity
900
800
700
Conductivity (mS) at 25°C
600
HCl
500
NaOH
KCl
400
NaCl
300
200
100
0
0 10 20 30 40 50 60
Concentration (% by weight)
How It’s Measured
Ohm’s Law
Where: E = Voltage I = Current R = Resistance
 E = IR
 Conductance, K, is defined as the inverse of resistance
 K = 1/R
 therefore R = 1/K
 E = I/K
 K = I/E
  By applying a constant voltage, E, and measuring the
current, I, the conductance, K, is calculated
Effect of Temperature - Conductivity of Sodium Chloride
6000
Conductivity (Scm-1)
5000
100oC
4000
3000 50oC
2000
1000 25oC
0
0 200 400 600 800 1000
Parts per million

Effect of Temperature - Conductivity of Sodium Hydroxide
120
Conductivity (Scm-1) x 10-3
100oC
100
60oC
80
60 25oC
40
20
0
0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0
% by weight
Relationship between Conductivity and Temperature
Kt = K25[ 1 + (t - 25)]

Where:
Kt = conductivity at temperature t
K25 = conductivity at the standard
temperature (25oC)
 = temperature coefficient per oC
Temperature Coefficients
Solutions Temperature Coefficient
Weak, aqueous
(K= <15000 Scm-1) 2% per 0C
Moderate strength acids 1.0-1.6% per 0C
Moderate strength alkalis 1.8-2.2 % per 0C
Moderate strength salts 2% % per 0C

Sensor Technology
 Two Electrode
 Four Electrode
 Toroidal (Electrodeless)
Two Electrode
AC
Load
Electrodes
-
- H
+
-
+
+
+
+
-
-
+
+
-
-
W
L
Area = W X H
Two Electrode - Cell Constants
Choosing the Right Cell Constant

0.01, 0.10, 1.0, 10, 100 ???
Load
Load
+ +
-+ +
+ - +
-+ - -+-+ - +
+ + -
- - - -
-+ +- - + - +- - -
- + - + - -
- - - + + + - + +
- -
+
+ + -+ + - + + + -+
+ -+
+ - - - -
+
++ - - - - - - -
-+ - -
- + ++ + + +
- - -
+ - -+ -+ - + + -
+ + - -
+ -
-
- -
-
0 1000
+
+ + µS/cm
+ -
Two Electrode - Cell Constants
Cell Constant = L/A (units 1/cm)

The conductance of
A For simplicity sake, let’s assume
Sensor A in a given
the distance of the electrodes from
each other is the same, L1 = L2 = 1 solution is 200 µS.
L1 The conductance of
Sensor B in the same
Cell const. of sensor A:
A1 solution is 2000 µS!
Given A1 = 1,
B then Cell Constant = 1 By normalizing the
Cell const. of sensor B: readings using the cell
Given A2 = 10, constants as a
then Cell Constant = 0.10 multiplier, both sensors
now produce a reading
Other Possible Cell Constants: of 200 µS/cm.
0.01, 0.05, 0.50, 5, 10, 100
L2 A2
Two Electrode Conductivity
 Apply Voltage
 Measure Current
 Compute Resistance (Conductivity)
 Control Current (and polarization) by changing cell constant of the sensor
INSTRUMENT SENSORWIRING SOLUTION
LeadResistance Interface
Resistance
Solution
Conductivity Resistance
Indicator
(Conductivity)
ACSource(fromAnalyzer)
Constant Voltage LeadResistance
Interface
R esistance
Four Electrode Conductivity
 Current Electrodes (Same as Two Electrode)
 Potential Electrodes
 Maintain Constant Voltage in Solution (Compensates for Scale and
polarization)
To comparator and 1 A specific drive (reference)

dirty sensor alarm
voltage is determined for
RI RI
2 each level of conductivity
Oscillator
RC by the microprocessor.
RI
3
Very High Impedance Amplifier Thus the instrument
RI
4
controls the maximum
current and resultant
polarization. There is no
need to change a sensor
Conductivity Sensing
Circuit and Display 1 & 4 Current Electrodes constant.
Ground 2 & 3 Voltage Electrodes
RC= Resistance of the liquid, the solution conductivity

RI = Interface Resistance: Erroneus resistance from foulants and polarization
Compensated by Four Electrode Conductivity Technique
Toroidal/Electrodeless
Drive Sense
Voltage T.C.
Current
Conductivity
Sensor
Cable
PEEK Temperature
Housing Compensation
Element
Process Induced Process

Solution Current Solution
In Out
Toroid
Toroid Sense
Drive Coil Coil
Advantages of Each Method
2-Electrode 4-Electrode
• Better for low conductivity  Better for higher conductivity
applications applications
– Stability  Reduces errors due to:
– Accuracy  Cable resistance
• Limited geometry effects  Coating and fouling
• Pre-calibration
 Polarization
• Longer cable runs
(high signal/noise ratio)  Wide Rangeability of single
sensor
 Dirty Sensor Alarm
Advantages of Each Method
Toroidal (Inductive)
 Ideal for corrosive to high conductivity applications
 Resists fouling due to oils and coatings
Technical Disadvantages
 Two Electrode
 Inaccuracies Due to Scale
 Polarization affects as conductivity increases
 Four Electrode
 Geometry Effects of open face sensor
 Can be susceptible to corrosion in high salts etc.
 Toroidal
 Accuracy poor below 400 uS/cm
 Geometry Effects
 No warning of heavy fouling
Toroidal
4-Electrode
2-Electrode
X
Ultra Pure
X
Pure
X
X
Demineralized
Boiler Feed
X
X
(Large Boiler)
Boiler Feed
X
(Small Boiler)
Recommended Applications
X
X
Condensate
X
Cooling Tower
High
X
X
Conductivity
%
X
X
Concentration
Corrosive
X
Service
Oil & Grease

X
Present
Recommended Ranges
pure medium boilers cooling concentration measurements

ultra pure clean drinking process waters
Two Electrode Sensors
Four Electrode Sensors
Toroidal / Inductive Sensors
0 uS 1.0 uS 50 uS 1000 uS 50,000 uS 500,000 uS

0.5 uS 10 uS 100 uS 10,000 uS 100,000 uS 1000,000 uS
Good Range for Sensor Weaker Range for Sensor

In-Line/Ball Valve Installation
 Horizontal Pipe
 Vertical Pipe, Upflow Only
 Between 1:00 and 5:00
 Non-Flashing Areas
 90 Degrees to Flow
Submersion Installation
 Keep Sensor Submerged

 Protect Rear of Sensor from Moisture
 Make Connections Above Liquid Level
 If Entrained Air, Mount at an Angle
Other Installation Considerations
 Run Signal Cable Alone in Conduit

 Install Transmitter Near Sensor
 Pipe/Container
 Proximity
 Material
 Air/Liquid Interface
Calibration
 Electronic
 Grab Sample
 Standard Solutions
Electronic Calibration
 Y = mX + b
 Y = Conductivity Reading
 m = Gain (Span)
 Inherent Sensor Characteristic
 X = Sensor output in mV
 b = Offset from Zero
 Geometry Effect
Grab Sample Considerations
 Pull Sample Near Sensor

 Note Transmitter Reading
 Immediately Measure Sample
 Adjust for the Difference
 Gain or Offset?
 SmartCal Advantage
Standard Solutions and Industrial Conductivity Sensors
 Standard Solution Integrity

 Less Than 1270 microsiemans/cm unstable
 Beaker
 Air/Liquid Interface
 Process Piping
Sensor Cleaning
 Can Use Both Chemical and Physical

 Remember Electrodes are Usually 316SS
 Sensor Body is Usually 316SS
Specific Cleaners
 Water Hardness
 Use 1% to 5% HCl
 Dip Sensor Until Scale is Removed
 Minimize Contact of Metal Components
 Rinse Well with Clean Water
Specific Cleaners
 Organic Coatings
 Use Isopropyl Alcohol
 Dip Sensor Into Solvent
 Remove Solvent with Clean Cloth
 Do Not Use Solvents that Harm Plastic Parts
Specific Cleaners
 Physical Cleaning for Thick Scales and Coatings

 Rag
 Tooth Brush
 Acid Brush
Parameters Effecting Conductivity Measurements
 Sensor Technology
 Sensor Installation
 Sensor Calibration
 Sensor Maintenance
Optimization of Conductivity Parameters
 Get the Right Tool for the Job

 Install in a Smart Location
 Calibrate In Situ
 Clean the Sensor
Questions?
Carson City, Nv - 37 -
01-04-06 -
Thank You!

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Theory, Installation,

 Nonspecific measurement of a fluid comprised of dissolved solids,

Parts per million

Kt = K25[ 1 + (t - 25)]

Solutions Temperature Coefficient

Moderate strength acids 1.0-1.6% per 0C

Moderate strength alkalis 1.8-2.2 % per 0C

Moderate strength salts 2% % per 0C

Choosing the Right Cell Constant

Cell Constant = L/A (units 1/cm)

INSTRUMENT SENSORWIRING SOLUTION

To comparator and 1 A specific drive (reference)

RC= Resistance of the liquid, the solution conductivity

Process Induced Process

Oil & Grease

pure medium boilers cooling concentration measurements

Two Electrode Sensors

Four Electrode Sensors

Toroidal / Inductive Sensors

0 uS 1.0 uS 50 uS 1000 uS 50,000 uS 500,000 uS

Good Range for Sensor Weaker Range for Sensor

 Keep Sensor Submerged

 Run Signal Cable Alone in Conduit

 Pull Sample Near Sensor

 Standard Solution Integrity

 Can Use Both Chemical and Physical

 Physical Cleaning for Thick Scales and Coatings

 Get the Right Tool for the Job

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