Plating Application: Chromic Acid Tank Level

Plating acid tanks.

Chromium is widely used in the metal finishing industry for both decorative and hard-chrome plating. The chemicals used in Chrome plating are very harsh and corrosive. Chromium plating requires that the metal to be plated to be pretreated in a sodium cyanide/caustic soda bath and then plated in a chromic acid bath.

A large international plating company located in the USA needed a cost effective liquid level switching that would perform flawlessly on their chemical plating baths.

Problem

The chemicals used in plating, specifically Chromic Acid, are extremely corrosive. Many times these chemicals need to be kept at elevated temperatures, resulting in corrosive vapors. Controls installed in and around areas where vapors are present are adversely affected.  For this customer, the tank level instruments near the chromic acid tanks were the most problematic.

Solution

Levelpro PLF

Icon Process Controls, a manufacturer specializing in corrosion resistant fluid handling instrumentation, recommended their Levelpro PLF series plastic level switch. The Levelpro PLF provides excellent chemical resistance. Body materials are available in PVC, PP, PVDF, or 316SS. The level switch is available is sizes from 6" to 10 feet, with up to 8 different switch points, and unlike ultrasonic sensors, the PLF Series are not affected by foam, vapor, or turbulence. Additionally, they require no power and are available in N/O or N/C switch positions.

The PLF series can be used to indicate high and low levels, notification of upset conditions or turn pumps or valves on-off. They are also an excellent choice for redundant high| low level indication when used in conjunction with a continuous level sensor.

For more information, contact M.S. Jacobs and Associates. They can be reached at 800-348-0089 or you can visit their web site at https://msjacobs.com.

How They Work: Magnetically Coupled Liquid Level Indicators (Mag Gauges)

Magnetically coupled liquid level indicators are in widespread use throughout today's process industries.

Originally designed as an alternative to site and gage glass devices, MLI’s are now commonly utilized in both new construction and plant expansions. Orion Instruments magnetic level indicators are precision engineered and manufactured to indicate liquid level accurately, reliably, and continuously.

As shown in this video, a float designed for the specific gravity of the process liquid travels inside the MLI chamber tracking the rise and fall of the process media.

This float contains an internal magnetic assembly that couples with the external visual indicator. The individual “flags” or “flippers” rotate 180 degrees as the level rises and falls, indicating the position of the liquid inside the MLI, and therefore, indicating the level of the liquid in the vessel.

These units are completely sealed and require little to no periodic maintenance. MLI’s also eliminate fugitive emission and glass breakage concerns common with site and gage glasses.

To complement these products, level switches and transmitters are available to further expand the control and alarm capability of the MLI.

For more information on magnetic level indicators, contact: M.S. Jacobs and Associates by calling 800-348-0089 or by visiting https://msjacobs.com.

Storage and Process Tanks

Industrial process tanks use measurement instruments
to reveal the nature of their contents.

Storage and process tanks are employed throughout a broad range of industrial, research, and commercial applications. The design and construction of the vessels varies widely, but there are a few measurement and control functions common to almost all applications. Whether general purpose or very specialized, a process or facility operator with a tank will need to know…

• Nature of the contents. What is in the tank.
• Quantity of material in the tank. This can be expressed as weight, mass, level or volume.
• Condition of the material in the tank. This can include temperature, pressure, or a range of other specific attributes which may have a bearing on the process or operation for which the material is to be used or applied.

Instrumentation and fixtures of varying styles and types are used to provide information relating to the three areas noted above. A broad range of tank level measurement techniques and instruments are employed to quantify tank contents. Specialized sensors can be used to measure conductivity, pH, and a host of other material aspects.

Industrial storage tanks are used as containers for everything from water to fuels to chemicals. Contents may be pressurized or blanketed with ignition suppressing gases, such as nitrogen. The construction of a process tank must meet requirements for safety and functionality related to its specific use. Well known commercial applications include those in food, beverage, and dairy sectors. Every industrial or commercial use will have standards for physical safety, product safety and quality, as well as requirements for effective integration into whatever system the application presents.

Mixing tanks perform a different function in the control process as opposed to storage tanks. Mix tanks are involved in batching and blending processes. Made of glass, plastic, sturdy rubber, or stainless steel, mixing tanks blend different substances together to create materials for production. The refined mixing process occurs as certain amounts of liquids are funneled into the tank from lines leading to the tank. The tanks may be provided with specialized fixtures or apparatus to facilitate the combining of constituent substances. Depending upon the application, the components may not all be liquid.

The term “tanks”, per se, encompasses practically an entire industry in itself. The variety of sizes, forms, materials, and accessory features is enormous. Share your tank instrumentation and measurement challenges with process measurement specialists, leveraging your own knowledge and experience with their product application expertise to develop an effective solution.

Differential Pressure Gauge for Level Indication on Liquefied Gas Tanks

A differential pressure gauge can be used to
indicate liquid level in tanks of liquefied gas
Image courtesy Wika

Wika, globally recognized leader and innovator in the design and manufacture of pressure and temperature gauges, provides an enormous number of variants and models of its basic pressure gauge. Many of the gauges are targeted at specific applications, and incorporate a range of design and operational features to accommodate the needs of those applications.

The Cryo Gauge is designed to provide indication of the level of liquid in liquefied gas tanks, but can also serve in some other related applications. For cryo tank applications, several available measuring cells provide operating ranges that cover the most commonly used tank sizes and gas types. An optional manifold with a separate pressure gauge provides connectivity and an indication of working pressure, all in one compact station. Options for analog output, level switches, and remote data transfer are part of the flexible configuration.

More detail on the Cryo Gauge is provided in the datasheet included below. Whatever the application, share your pressure measurement challenges with process measurement experts, leveraging your own knowledge and experience with their product application expertise to develop effective solutions.

Process Differential Pressure Gauge from MSJacobs-Cali

Tank Overfill Protection - Level Measurement Technology Resources for Best Results

Crude oil storage tanks, a beneficiary of overfill protection

Industrial liquid processing often includes tanks or other vessels for the storage or combining of product components, raw materials, or finished product. Regardless of the nature of the liquid, overfill and spillage are of concern due to economic loss, downtime, and the creation of hazardous conditions. Good practice calls for detection of overfill conditions in a reliable manner which will provide operators notice of the condition in time to avoid spillage.

Magnetrol®, a globally recognized leader in the field of liquid level measurement, has created a set of resources to help customers understand the need for overfill protection and properly establish a protocol. Different industries and products will have varying levels of risk or hazard, thus different governing standards. The basic benefit to overfill protection is the same throughout...whatever is in the tank should be contained. Included below is one of several resources provided by Magnetrol® to address the issue of overfill protection. You can get the entire set by contacting level control specialists.

There are a number of technologies employed in the measurement of liquid level. Each has its own set of attributes that may prove advantageous for a particular application. Share your level measurement and control challenges with a product application specialist. Combining your process expertise with their product application knowledge will produce effective solutions.

Tank Overfill Protection Minimizing Insurance Risk from MSJacobs-Cali

Level Measurement: Comparing Displacer Transmitters and Differential Pressure Transmitters

Electronic Displacer Transmitter
Courtesy Magnetrol

Liquid level measurement is ubiquitous throughout industrial fluid processing operations. Whether via direct or inferential means, the fluid level data point is an integral part of operational and safety plans for an installation.

Magnetrol, a globally recognized leader in the design and manufacture of level measurement instrumentation, has produced a comparison of displacer transmitters and differential pressure transmitters applied to liquid level measurement.

What is a displacer transmitter?

Displacer transmitters are considered a direct means of level measurement.

Quoted from Magnetrol website page on displacer transmitters...

Electronic displacer level transmitter technology operates by detecting changes in buoyancy force caused by liquid level change. These forces act upon the spring supported displacer causing vertical motion of the core within a linear variable differential transformer.
As the core position changes with liquid level, voltages are induced across the secondary windings of the LVDT. These signals are processed in the electronic circuitry and used to control the current in the 4-20 mA current loop. The enclosing tube acts as a static isolation barrier between the LVDT and the process media.

 How does a differential pressure transmitter measure liquid level?

Liquid level can be inferred through the measure of the pressure generated by the column of liquid in a tank or vessel. The measurement device must be calibrated for the specific gravity of the measured media in order to attain reasonably accurate results. There are a number of installation arrangements of differential pressure transmitters that will accommodate tanks open to atmosphere, closed pressurized tanks, and more.

The comparison is included below and provides some interesting points to consider. Share your level measurement application challenges with a product application specialist. Combining your process experience and knowledge with their product application expertise will produce the best solutions for your process measurement needs.

Comparing Level Measurement Methods: Displacment Transmitter vs Differential Pressure Transmitter from MSJacobs-Cali

Orion Instruments Announces New Level Transmitter

Direct insertion and external mount versions of
Orion JM4 Magnetostrictive Level Transmitter
Courtesy Orion Instruments

Orion Instruments, a world class manufacturer of magnetic level indicators, level switches, and level transmitters, has released a new product for use in the industrial process measurement and control field. Their Jupiter Model JM4 magnetostrictive transmitter incorporates the company's many years of research, development, and field experience to provide a safer, simpler, and smarter transmitter for liquid level measurement and control.

The new model from Orion boasts level measurements with accuracy as high is +/-0.05" (1.27mm). The transmitter head can be rotated up to 310 degrees with an option for remote mounting. Variants are available for direct insertion or external mounting, with approvals for a number of area classifications. There are other valuable features to this series of level measurement instruments that reflect Orion's expertise in the field.

Browse the new product brochure included below. It provides illustrations of the product and its operating principle, along with dimensioned drawings and a listing of all the product options and variants. You can always obtain whatever information you need about Orion level measurement instruments from a product specialist. Share your liquid level measurement challenges and requirements with them for recommendations on the best solutions.

Orion Jupiter JM4 Magnetostrictive Level Transmitter from MSJacobs-Cali

Knowledge Base and Selection Guide For Magnetic Level Indicators

Magnetic Level Indicators
Courtesy Orion Instruments

Industrial process control frequently involves the storage of liquid in vessels or tanks. Continuous and accurate indication of liquid level within the tank is an essential data point for safety and process management. While there are a number of methods and instrument types utilized to provide tank level measurement, the instrument of choice is often a magnetic level indicator, also referred to as a magnetic level gauge. Its use for providing level indication has a number of positive attributes:

• Construction that is resistant to breakage.
• Measuring indicators, switches, and transmitters mounted externally, without contacting the medium being measured.
• Maintenance free operation. No regular cleaning needed.
• Readable level indication from greater distance than glass sight gauges.
• Magnetic level indicators can accommodate greater fluid level ranges without the need for multiple instruments.

Orion Instruments, a Magnetrol company and industry leader, has produced a comprehensive guide to magnetic level gauges, switches, transmitters, and related products. It delivers experts and newcomers an understandable and clear description of the technology and principals of operation behind magnetic level gauges and instruments. The guide also assists the reader in properly specifying and selecting the best instrument configuration for an application. A table of contents at the front of the document helps readers to quickly find the information they need.

Take a couple minutes to roll through the document and you are likely to find new and useful application tips and product information. Any questions about magnetic level indicators or your process measurement and control applications can be clearly addressed by a product specialist.

Orion magnetic level selection guide from MSJacobs-Cali