ECHOTEL CONTACT ULTRASOUND. Worldwide Level and Flow Solutions SM

Transcription

1 ECHOTEL CONTACT ULTRASOUND Worldwide Level and Flow Solutions SM

2 The Total Spectrum of Solutions Magnetrol products employ a number of technologies to meet the challenges of level and flow measurement. Echotel contact ultrasonic switches utilize continuous wave and pulsed signal ultrasound for accurate and reliable liquid level measurement. MAGNETROL CONTACT ULTRASOUND

3 Magnetrol International a world leader in level and flow measurement technology designs, manufactures, markets and services level and flow instrumentation worldwide. Magnetrol s product groups are based upon these technologies: Air Sonar Buoyancy Contact Ultrasound Guided Wave Radar RF Capacitance Thermal Dispersion Vibration Visual Indication The industries we serve include: Petroleum Production Petroleum Refining Power Petrochemical Chemical Water & Wastewater Pulp & Paper Food & Beverage Pharmaceutical An Introduction to Ultrasonic Level Sensing Continuous-Wave and Pulsed-Signal Sensing Self-Test Capabilities Application Guidelines Advantages and Limitations of Ultrasonic Sensing Echotel Contact Ultrasound Product Line Model 910 Models 911 and 921 Models 915P and 915W Models 919F and 919R Models 91S and 92S Hot Tap Assembly for Echotel

4 An Introduction To Contact Ultrasonic Level Sensing Ultrasound technology was developed during WWII under the acronym SONAR (SOund Navigation And Ranging). Ultrasonic level measurement entered the process control industry in the 1960s and today it continues to play a significant role in liquid level measurement and control. Ultrasonic level instruments fall into two groups: Those which are designed for non-contact sensing and those which come into direct contact with process media. This brochure focuses on Magnetrol s contact instruments which are used for point level measurement. Continuous-Wave and Pulsed-Signal Sensing Contact liquid level sensing is achieved by one of two ultrasonic technologies: Continuous-Wave or Pulsed-Signal technology. Continuous-Wave switches have two piezoelectric crystals mounted opposite each other in a transducer body, separated by a gap. The transmit crystal produces an acoustical signal when subjected to an applied voltage from an amplifier circuit. The receive crystal converts the acoustical signal it receives into an electrical signal, which becomes the input of the same amplifier circuit. When liquid is present in the transducer gap, the amplifier becomes as oscillator causing a relay circuit in the electronics to indicate a wet gap condition. When liquid vacates the gap, the amplifier returns to an idle state. In Pulsed-Signal units a digital electronic amplifier produces a powerful pulse of Challenging process ultrasonic energy five to ten times conditions such as more powerful than most continuous wave units. This allows meas- suspended solids or aeration are best urement in conditions that include managed by pulsedsignal ultrasonic aeration, suspended solids, turbulence, and highly viscous liquids. level switches. The effects of mild Pulses of high-frequency turbulence can ultrasonic energy milliseconds in be minimized by duration are produced by the choosing a switch with an adjustable transmit crystal. In between each time-delay circuit. pulse the receive crystal listens for the transmission. If liquid is present in the gap the receive crystal detects the pulse and reports a wet gap condition to the electronics. When the gap is filled with air, the receive crystal cannot detect the pulse, and reports a dry gap condition. T R Contact ultrasonic level switches use ceramic discs called piezoelectric crystals to transmit and receive ultrasonic energy. A transmit crystal (T) is on one side of a transducer gap and a receive crystal (R) is on the opposite side. Tip-sensitive style gaps (left) can sense level within 1 4" from the end of the transducer, while the side-gap style (right) must be completely filled with fluid before liquid level is sensed. T R 4

5 Ultrasonic Level Measurement Solutions for Every Industry Self-Test Capabilities An ultrasonic switch is often used as the last means of detecting whether a vessel will overflow and cause a spill, or empty out and possibly cavitate the pumps. In these critical applications a method of periodically testing the ultrasonic switch to ensure proper functioning is desirable. Several Echotel units offer self-test capabilities that can be performed automatically several times per second or manually with a magnet or push button. An advanced self test is also offered on several pulsed technology units to test bonding integrity of the piezoelectric crystals to the transducer gap. Application Guidelines Contact ultrasonic level switches are not affected by changes in liquid properties such as specific gravity, conductivity, ph, and dielectric or temperature shifts. Turbulent liquid applications can cause false level alarms, especially if the process media is a viscous liquid with suspended solids. Echotel switches remedy this by offering time delay Tip-Sensitive Transducer circuitry and through the use of a tip-sensitive transducer design. Several units offer an adjustable time constant that resolves false alarms with rising and/or falling liquid levels. Tip-sensitive transducers drain liquids and air bubbles more efficiently from the sensor gap, and are more reliable in difficult process conditions. Advantages and Limitations The advantages of contact level sensing are: Low cost single and dual-point sensing. Accurate and reliable in a variety of liquids. Easy installation and simple configuration. A broad range of sensor materials are available. Transmits a stable signal despite liquid property changes. Switches contain no moving parts for long life and low maintenance. Certain process conditions may interfere with the ultrasonic signal. These conditions include: Slurries with a very high percentage of solids. Extreme aeration of the liquid. Media which generate crystallized coatings. Aggressive turbulence and splashing. At a Glance: Magnetrol s Agency-Approved Ultrasonic Switches MODEL ULTRASOUND TECHNOLOGY SET POINTS SENSOR STYLE MOUNTING 3A VERSION SELF-TEST TIME DELAY 910 Continuous Wave Single Tip Integral 911 Continuous Wave Single Side Integral or Remote 921 Continuous Wave Dual Side Integral or Remote 915W Pulsed Signal Single Tip Integral 915P Pulsed Signal Single Tip Integral 919F Pulsed Signal Single Tip Integral 919R Pulsed Signal Single Tip Integral 91S Pulsed Signal Single Tip Integral or Remote 92S Pulsed Signal Dual Side Integral or Remote 5

6 910 Level Switch An industry leader featuring a 10 amp DPDT gold flash relay field-selectable for high or low level failsafe. Worldwide safety approvals, 2-year warranty. Proximity Sensing The Model 910 measures liquid level within 0.25" (6 mm) from the end of the tip-sensitive transducer. When used as a low level switch, it can measure level further down into a tank or vessel. Model 910 Omni-Directional Mounting Model 910 may be mounted horizontally or vertically. Mounting options include NPT and BSP threaded, flanges and sanitary connections. Worldwide Safety Approvals With FM, CSA and CENELEC approvals on one agency nameplate, this is the perfect switch for OEM applications with global customer destinations. Liquid Level Applications Model 910 Electrical Specifications Power Supply 120 VAC (+10%/-15%), 50/60 Hz 240 VAC (+10%/-15%), 50/60 Hz 24 VDC (±10%) Power Consumption 2.5 VA nominal Relay Output Gold Flash DPDT, VAC, 240 VAC, or 24 VDC Hermetically-Sealed DPDT, 5 VAC, 240 VAC, 24 VDC Repeatability 0.078" (2 mm) Fail-Safe Field selectable high or low Ambient Temperature Electronics -40 to +160 F (-40 to +71 C) Process Temperature Transducer -40 to +250 F (-40 to +121 C) Operating Pressure 800 psig (55 bar) maximum PROCESS MEDIA: Clean liquids Low viscosity liquids Liquids with low % solids Corrosive liquids OF SPECIAL INTEREST TO: Wastewater treatment Oil and gas industry OEM and skid manufacturers 6

7 911/921Level Switch Single and dual point continuous wave ultrasonic switches for liquid applications having low viscosity, low aeration and low percent of solids. Single and Dual Gap Models The Model 911 (single gap) and Model 921 (dual gap) are available in a broad choice of transducer materials that between them include 316 Stainless Steel, CPVC, Hastelloy B or C, Kynar, Monel, Polypropylene, and Teflon. Adjustable Time Delay and Self-Test An adjustable time delay compensates for splashing or turbulence of the process fluid. Both models 911 and 921 feature local and remote self-test capabilities. Above: Single point model 911 Right: Dual point model 921 Integral or Remote Electronics Models 911 and 921 are available with integral or remote electronics. The single-gap model 911 can be mounted horizontally or vertically. The dual-gap model 921 is always top-mounted. Liquid Level Applications Model 911/921 Electrical Specifications Power Supply 120 VAC, 50/60 Hz (+10%/-15%) 240 VAC, 50/60 Hz (+10%/-15%) 24 VDC, (±10%) 12 VDC, (±10%) Output Signal Gold Flash Relay DPDT, VAC, 240 VAC, or 24 VDC Hermetic Relay DPDT, VAC, 240 VAC, or 24 VDC Power Consumption 2.5 VA nominal Repeatability 0.078" (1.98 mm) Fail-Safe Field selectable high or low Time Delay 0-60 seconds nominal Self Test Local magnetic or jumper Remote by push button Ambient Temperature -40 to +160 F (-40 to +71 C) Process Temperature -40 to +250 F (-40 to +121 C) Operating Pressure 800 psig (55 bar) maximum PROCESS MEDIA: Clean liquids Low viscosity liquids Light slurries Acids and caustics OF SPECIAL INTEREST TO: Chemical plants Hydrocarbon processors Power generation 7

8 915 Level Switch Two-wire, loop powered integral switches utilize pulsed signal technology to detect high or low level in a broad range of liquids. Hi-Performance Ultrasound Pulsed signal technology offers superior performance in difficult conditions (aeration, foaming, suspended solids); and provide immunity from noise interference. The surface mount electronics are completely encapsulated in a potted module for maximum protection. Choice of Transducer Materials Model 915P is available with 316 stainless steel, Hastelloy C, or Monel transducers. Model 915W is available with a Kynar transducer in a 3 4" NPT and Kynar faced-flange options. Above: 915P with 316 SS transducer and flange. Right: 915W with Kynar transducer. Continuous Self-Test The continuous self-test performs a diagnostic check of electronics, transducer and piezoelectric crystal bond integrity several times per second in both wet and dry gap conditions. Model 915 Electrical Specifications Power Supply VDC (24 VDC nominal) Power Consumption 1 watt maximum Signal Technology Pulse (electronic windowing) Output Normal Operation 16 ma ±1 ma Alarm Condition 8 ma ±1 ma Malfunction 5 ma ±1 ma LED Indication Normal Green LED on Alarm Red LED on Malfunction No LED s on Response Time 0.15 second typical Repeatability ±0.078" (2 mm) Ambient Temperature -40 to +160 F (-40 to +70 C) Process Temperature 915P -40 to +300 F (-40 to +150 C) 915W -40 to +250 F (-40 to +120 C) Maximum Pressure 915P F ( C) 915W F ( C) Liquid Level Applications CONTROL FUNCTIONS: High/Low level alarm Overfill protection Pump protection Leakage detection Tank fill monitoring Valve actuation 8

9 919 Level Switch A pulsed signal ultrasonic switch in a compact, integral Valox housing that performs high or low level control in a variety of liquid applications. Choice of Electronics Your choice of electronics is housed in a watertight, corrosion resistant Valox housing that s rotatable for easy conduit alignment. Model 919R is a 24 VDC unit featuring a 3 amp SPDT relay output. Model 919F is an all-voltage version that operates from 24 to 240 volts AC or DC. Model 919 with Sanitary Flange Pulsed Signal Technology Pulsed signal technology excels in difficult conditions that may cause other ultrasonic switches to falter. The technology also provides excellent immunity from electrical noise that is common in many industrial applications. 3-A Authorized Sanitary Version The 3-A authorized sanitary transducer option has a 20 Ra surface finish and a unique, crevice-free sensor tip that enhances cleanability during the Clean-In-Place process. All transducers may be mounted horizontally or vertically. Model 919 Electrical/Environmental Specifications Power Supply All Voltage VAC ±10% Hz VDC ±10% Relay 24 VDC (±10%) Power Consumption All Voltage 0.1 VA maximum Relay Less than 1 watt Signal Output All Voltage 500 ma (continuous) maximum 7.5 ma (continuous) mininimum load Relay SPDT 3 30 VDC resistive and VAC resistive Repeatability 0.078" (2 mm) Response Time 1 2 second typical Ambient Temperature Electronics -40 to +160 F (-40 to +70 C) Process Pressure 1500 psig (103 bar) maximum Process Temperature Without Heat Extension -40 to +250 F (-40 to +120 C) With Heat Extension -40 to +300 F (-40 to +150 C) Liquid Level Applications CONTROL FUNCTIONS: High/Low level alarm Overfill protection Pump protection OF SPECIAL INTEREST TO: Food & Beverage Pharmaceutical Generic chemicals Biotechnology 9

10 91S/92S TRIDENT Level Switch Available with a current shift or 10 amp DPDT relay output, Trident single and dual-point switches offer an advanced, continuous self-testing technology. Choice of Electronics Current-Shift Version is a 24 VDC switch that produces an 8mA output without liquid in the gap, and 16mA with liquid in the gap.there is also a field-selectable malfunction output of either 5mA or 19mA for fault conditions. Relay Version has a 10 amp, DPDT gold flash process relay(s) and a dedicated 10 amp SPDT gold flash malfunction relay. Model 91S Continuous Self-Test The self-test function continuously tests the integrity of the electronics, transducer and piezoelectric crystal bond. The self-test can also run manually by pushing a button on the PC board or, remotely, by wiring an external pushbutton to a terminal block provided on the unit. Adjustable Time Delay To contend with turbulent process conditions, Trident switches incorporate a time-delay feature. The delay is adjustable from half a second to a full 30 seconds and can be set for rising or falling tank levels. Liquid Level Applications Model 92S CONTROL FUNCTIONS: High or Low level alarm Overfill protection Pump control & protection Seal pot level 10

11 TRIDENT Electrical Specifications Hot Tap Assemblies Allows installation or removal of Echotel without a process shut-down Trident Current Shift Specifications Supply Voltage VDC Current Loop Loads 650 ohms with 24 VDC source 1200 ohms with 35 VDC source Output Process 8 ma (dry) or 16 ma (wet) Malfunction 5 ma or 19 ma for fault conditions Self-Test Continuous Verifies operation of electronics, transducer, and crystal bonding Manual Local push button to force a malfunction condition Time Delay Adjustable seconds on rising and/or falling liquid level Fail-Safe Field selectable, high or low level Repeatability ±0.078" (1.98 mm) Power Consumption 1 watt maximum Ambient Temperature -40 to +160 F (-40 to +71 C) Process Temperature -40 to +325 F (-40 to +163 C) Maximum Pressure to +325 F ( to +163 C) Trident Relay Specifications Supply Voltage 12, 24, or 48 VDC (±10%) 120 or 240 VAC (+10%/-15%), 50/60 Hz Relay Outputs 91S One process, one malfunction 92S Two process, one malfunction Relay Ratings Process 10 amp DPDT, gold flash contacts Malfunction 10 amp SPDT, gold flash contacts Self-Test Continuous Verifies operation of electronics, transducer, and crystal bonding Manual Local or remote push button to force a malfunction condition Time Delay Adjustable seconds on rising and/or falling level Fail-Safe Field selectable, high or low level Repeatability ±0.078" (1.98 mm) Power Consumption 2.50 VA nominal Ambient Temperature -40 to +160 F (-40 to +71 C) Process Temperature -40 to +325 F (-40 to +163 C) Maximum Pressure to +325 F ( to +163 C) Standard Hot Tap design (above); high pressure design (below). With a Hot Tap assembly in place, an Echotel switch can be installed or removed from a pipe or vessel while the process remains in operation. There s no need to drain or depressurize the tank or shut down the operation in order to install or remove the instrument. Echotel Hot Tap assemblies feature: Standard and High Pressure models 316 SS gland construction Carbon steel or stainless steel process connections Flange and ball valve optionally available 1 1 2" NPT or flange connection Teflon compression rings are standard 11

12 Worldwide Level and Flow Solutions SM CORPORATE HEADQUARTERS 5300 Belmont Road Downers Grove, Illinois USA Phone: Fax: BELGIUM: Heikensstraat Zele, Belgium Phone: Fax: BRAZIL: Av. Luis Stamatis 620-Jacana Sao Paulo CEP l CANADA: 6291 Dorman Road, #18 Mississauga, Ontario L4V 1H2 CHINA: Room #8008 Overseas Chinese Mansion 129 Yan An Road (W) Shanghai DEUTSCHLAND: Schloßstraße 76 D Bergisch-Gladbach (Bensberg) DUBAI: Suite 1F1 Hamarain Centre Abu Baker Al Siddique Road P. O. Box Dubai, United Arab Emirates FRANCE: Le Vinci 6 Parc d Activities de mitry Compans 1 rue Becquerel Mitry Mory INDIA (Sales Liaison Office): B4/115 Safdurjung Enclave New Delhi ITALIA: Via Arese, Milano SINGAPORE: 23 Woodlands Industrial Park E1 #04-01 Singapore UNITED KINGDOM: Regent Business Centre Jubilee Road Burgess Hill, West Sussex RH15 9TL Copyright 2002 Magnetrol International. All rights reserved. Printed in the USA. Bulletin: Effective: July 2002