a guide to level and flow controls for the chemical industry industry.pdf · a guide to level and...

A Guide to Level and Flow Controls for the Chemical Industry

I N D U S T R Y A P P L I C A T I O N S S E R I E S

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3

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REBOILER

TOWER

CONDENSER

CONDENSER

REFLUX DRUM

1-4: Distillation

TO STORAGE

5: Liquid Extraction

LIGHT PHASE

HEAVY PHASEMIXING SETTLING 5

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6: Vapor/Liquid Separation

VAPOR OUT

LIQUID OUT

FEED

CLEAN AIR OUT

SCRUBBERWATER IN

SCRUBBERWATER OUT

DIRTYAIR IN

7: Scrubber Vessel

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Leading Level and FlowChemical ApplicationsLiquid Level Applications:

The following level applications utilize levelinstruments for process control. A separatealarm using a different technology oftenserves as a back-up for spill detection.

1. Distillation Tower

2. Reboiler

3. Condenser

4. Reflux Drum

5. Liquid Extraction

6. Vapor/Liquid Separation

7. Scrubber Vessel

8. Mixing & Blending

9. Chemical Reactor

10. Fermentation Vessel

11. Steam Drum

12. Surge Drum

13. Catalysis Vessel

14. Chlor-Alkali Process

15. Chemical Injection

16. Deionization Tank

17. Waste Sump

18. Neutralization

19. Liquids Storage

20. Liquefied Gas Storage

Flow Applications:

21. Mass Air & Compressed Air

22. Process & Waste Gases

23. Tank Blanketing

24. Pump Protection

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7

IN

PRODUCT

8: Mixing Vessel

8

HEATSTEAM

PRODUCT

9: Chemical Reactor

COOLANT

SOLVENT, RAW MATERIALOR REACTANT

STERILIZATIONSTEAM

PRODUCT

10: Fermentation VesselSTERILE AIR

OFF-GAS

14: Chlor-Alkali

CHLORINE GASHYDROGENGAS

CAUSTIC

11: Steam Drum

FEEDWATER

PRODUCT

CATALYST

GAS FEED

GAS OUT

12

13: Catalysis Vessel

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12: Surge Drum

INLET

OUTLET

VENT

15: Chemical Injection

16: Deionization

WASTEWATER

18: Neutralization

TREATEDWATER

ACID & CAUSTIC FEED

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17: Waste Sump

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STEAM

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14

15

16UNTREATEDWATER

TREATEDWATER

19-20: Storage Tanks

19 20

21

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23

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21-24: Flow Applications

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10

IN 17

AIR/COMPRESSED AIR

PROCESS/WASTE GAS

TANK BLANKETING

PUMP PROTECTION

INFLUENTEFFLUENT

NaCl

Application: Selecting a separation technology fromamong 20 leading varieties depends upon a chemi-cal’s nature, the number of phases, and the capacity,speed and efficiency required. Distillation—separatingsubstances based on differences in volatilities—is themost widely used separation and purification method.Today, approximately 40,000 distillation towers areoperating in U.S. chemical plants.

Challenges: Level measurement at the bottom of adistillation tower controls the “bottoms” product rate.Poor level control could allow liquid to back up overthe stripping trays causing damage and reducedyields. Too low level may cause pump cavitation. Inrelated extraction towers, interface level control pro-vides optimal separation from associated substances.

DISTILLATION TOWERINSTRUMENTATION

Application: Reboilers, or vaporizers, are heatexchangers that provide heat to the bottom of adistillation tower. They boil the bottom liquid togenerate vapors which are returned to the towerto drive the distillation separation process. Thereboiler may partially or completely vaporize thestream it receives from the bottom of the tower.

Challenges: Excess reboiler liquids (bottomsor blow-down) overflow a baffle where level iscontrolled by means of a level controller. If thereboiler level becomes too low, it will affect themaximum flow rate of bottoms product that canbe drawn off. Inaccurate reboiler level can alsodegrade composition control for material balancecontrol configurations.

REBOILER

INSTRUMENTATION

Reboiler

Distillation and Extraction Towers

� Continuous Level:Eclipse® Model 705Guided Wave Radaror E3 Modulevel®

Displacer-ActuatedTransmitter

� Point Level:Series 3 Float-ActuatedExternal CageLevel Switch

� Visual Indication:Atlas™ or Aurora®

Magnetic LevelIndicators can besupplied with switchesor transmitters

� Continuous Level:ECLIPSE Model 705Guided Wave Radaror E3 MODULEVELDisplacer-ActuatedTransmitter

� Visual Indication:Atlas or AURORAMagnetic LevelIndicators can besupplied with switchesor transmitters

� Point Level:Series 3 Float-Actuated ExternalCage Level Switchor Tuffy® II Float-Actuated Switch

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Application: A heat transfer process that changes agas or vapor to a liquid, condensation is employed inthe reflux process to improve the efficiency of distilla-tion. Condensation can also be employed for produc-ing saturated liquid products, for sub-cooling, or toserve an environmental or vapor recovery function.Condensation is carried out in a variety of configurations.

Challenges: In the distillation process, tower vaporsare condensed prior to entering an accumulator.The condenser’s level can be used to control towerpressure where the liquid level set point serves as themanipulated variable (MV) for the pressure controller.Adjusting liquid level in the condenser changes theeffective heat-transfer area.

3 CONDENSERINSTRUMENTATION

Application: Large-scale distillation towers use areflux system to achieve a more complete productseparation. Reflux is that portion of a tower’s con-densed overhead liquid product that is cycled backto the top of the tower where it flows downward toprovide cooling and condensation of the upflowingvapors.

Challenges: The reflux drum, or accumulator,serves as a distribution point for reflux and distillate.Condensed liquid leaves the reflux drum under levelcontrol. Drum level control is critical to ensure that theproper amount of reflux will return to the distillationtower. Poor liquid level indication can cause expensiveoperating problems and product degradation.

4 REFLUX DRUM

INSTRUMENTATION

Reflux Drum

Glycol Regeneration with Condensers


� Continuous Level:ECLIPSE Model 705Guided Wave RadarTransmitter or E3MODULEVELDisplacer-ActuatedTransmitter


� Continuous Level:ECLIPSE Model 705Guided Wave RadarTransmitter



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Application: Liquid-liquid extraction (LLX), or solventextraction or partitioning, is a selective separationprocedure for isolating and concentrating a valuablesubstance from an aqueous solution by using anorganic solvent. LLX can serve as an alternative whendistillation is ineffective. LLX is used in pharmaceuti-cal, food and agricultural processing, organic andinorganic chemistry, hydrometallurgy and fragrances.

Challenges: In mixer-settler type extraction, feedand solvent tanks are monitored for level. The feedand solvent are thoroughly blended in a mixer-settlerchamber and the mixture overflows into a separationchamber where it settles into light and heavy phases.The separate phases are monitored and removed oninterfacial level control.

5 LIQUID EXTRACTIONINSTRUMENTATION

Application: Where the separation of vapors andliquids is required, a separator drum, or knockout pot,flash drum, or compressor suction drum, is integratedinto the process unit. The separation vessel receivesthe flashing liquid mixture where the liquid is subse-quently gravity separated and falls to the bottom asthe vapor exits at the top.

Challenges: Typically, a collection tank locatedbeneath the separation chamber collects the liquid bygravity flow and utilizes a liquid level control for liquidwithdrawal. The control also maintains a vapor barrierwhile discharging the collected liquid at the same rateof accumulation. In some separators, such as flashdrums, liquid level must be kept within an extremelynarrow span for very tight control.

6 VAPOR/LIQUID SEPARATION

INSTRUMENTATION

Flare K/O Drum

Extraction

� Point Level:Echotel® Model961 UltrasonicSwitch orTHERMATELModel TD1/TD2Switch

� Continuous Level:ECLIPSE Model 705Guided Wave RadarTransmitter or Jupiter®

MagnetostrictiveLevel Transmitter


� Point Level: Series3 Float-ActuatedExternal CageLevel Switch orThermatel® ModelTD1/TD2 ThermalDispersion Switch



6

Application: Scrubbers remove odors, pollutants,acid gases and chemical wastes from air and liquidstreams. In a wet scrubber, the polluted stream flowscounter currently past water or a liquid chemicalwhich removes the undesirable component of the gasor liquid. Chemical scrubbing typically requires largeamounts of caustic chemicals.

Challenges: Accurate level monitoring of the scrub-bing water necessitates a control to automaticallyfeed the correct amount of make-up water to therecycle reservoir either continuously or on a periodicbasis. Located in the wet scrubber shell, the levelmonitoring device for water-out control should beequipped with a level alarm.

7 SCRUBBER VESSELINSTRUMENTATION

Application: Mixing and blending of liquidingredients is essential throughout the broaderchemical industry. In-line and skid mountedsystems include batch and continuous mixingfor liquid/liquid formulation and blending. Animpeller in the process vessel accomplishesthe mixing of miscible liquids.

Challenges: A mixing and blending system canbe as simple as a vessel with an agitator andgraduate in complexity to a fully skid-mountedPLC controlled system with heating, cooling,homogenization and steam injection capabilities.Level controls monitor tank and vessel levels andtrigger alarms in underfill and overfill incidents.

8 MIXING & BLENDING

INSTRUMENTATION

Natural Gas Scrubbers

Mixing Tank


� Continuous Level:Pulsar® Model RX5Pulse Burst RadarTransmitter


� Point Level:ECHOTEL Model961 UltrasonicSwitch orTHERMATELModel TD1/TD2Switch

� Continuous Level:ECLIPSE Model 705Guided Wave RadarTransmitter orJUPITERMagnetostrictiveLevel Transmitter


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Application: Chemical, polymerization and pharma-ceutical processes utilize reactor vessels to containchemical reactions. Chemical reaction speed andproduct quality are frequently controlled by an exter-nal heat exchanger for elevating temperature and acryogenic system for lowering temperature. Reactorstypically contain impellers for product mixing.

Challenges: Level instrumentation in a tank-typereactor vessel must contend with diverse and oftenaggressive product chemistries, agitation, mixing,surface foam and temperature and pressurevariations. Low level monitoring in the dischargeline, high level monitoring in the vessel, andinterfacial measurement of the foam/emulsioninterface is recommended.

9 CHEMICAL REACTOR

INSTRUMENTATION

Application: Industrial fermentation is the process ofbreaking down organic substances and re-assemblingthem in order to produce other chemical compounds.Alternative fuels like ethanol and chemicals such asmethanol and a wide range of acids can be developedusing this process. Chemical fermentation takes placein large tanks called fermenters in a process that caneither be aerobic or anaerobic.

Challenges: Depending upon the type of fermentationvessel and the media being processed, the level controloften must contend with agitation and aeration. Frothor foam is typically generated because fermentationagents have surfactant properties. When processingacids, contact level controls must tolerate the veryaggressive media.

10 FERMENTATION VESSEL

INSTRUMENTATION

Fermentation Vessel

Chemical Reactor






� Point Level:ECHOTELModel 961Ultrasonic LevelSwitch

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Application: Chemical manufacturers are majorusers of steam for cleaning, drying, fermentation,steam stripping, and chemical recovery. Steaming-in-place (SIP) is a widely used method for in-linesterilization of vessels, valves, process lines, andfilter assemblies. Steam is created in a boiler whereheat transforms water under pressure into steam.

Challenges: Boiler drum level control is critical forsafe and efficient steam generation. Drum levelcontrol maintains level at constant steam load.Too low a level may expose boiler tubes, which willoverheat and sustain damage. Too high a level mayinterfere with separating moisture from steam, whichreduces boiler efficiency and carries moisture intothe process.

11 STEAM DRUM

INSTRUMENTATION

Application: Surge drums are frequently locatedbetween process units to help reduce the effect offlow rate variations between interconnected processunits. A low surge drum level can result in reducedcapacity while a high level can cause liquid carry-over. In an application characterized by alternatinginertia and turbulence, stable level output is highlydesirable.

Challenges: Contrary to the normal controlobjective of keeping a measurement at set point,the purpose of a surge drum level control is todampen the changes in controlled flow while keepingthe liquid level in the vessel between limits. For surgedrums it is generally more important to allow levelsto "float" in order to minimize flow rate variations.

12 SURGE DRUM

INSTRUMENTATION

Steam Drum

Surge Drum


� Visual Indication:Atlas or AURORAMagnetic Level Indicatorscan be supplied withswitches or transmitters

� Point Level:Series 3Float-ActuatedExternal CageLevel Switch


� Point Level:Model A15Displacer-Actuated LevelSwitch


9

Application: The catalytic method of convertingcompounds into other compounds uses a chemicalcatalyst to increase the rate of a reaction. Thecatalyst is chemically unchanged after the reactionhas occurred and can be recovered from the reactionmixture. Thirty of the top fifty commodity chemicalsare created directly by catalysis.

Challenges: In the fluidized bed reactor-regenerator(FBRR) a fluid is passed through the catalyst at highenough velocities to suspend the solid and cause it tobehave as though it were a fluid. Measurement in thereactor vessel must contend with severe processconditions. Finished product and, in some configura-tions, spent catalyst, is on level control.

13 CATALYSIS VESSEL

INSTRUMENTATION

Application: Chlor-alkali (CA) refers to chlorine andcaustic soda (NaOH) manufacturing. These areamong the top ten chemicals produced worldwideand are main ingredients in the manufacture ofpharmaceuticals, detergents, disinfectants,herbicides, pesticides and PVC. Chlorine and causticsoda are made by the electrolysis of brine (NaCl).

Challenges: In the preferred membrane process ofCA, level instruments control saturated brine anddemineralized water feed, and caustic liquid level.Level control maintains a high enough level in theanode and cathode compartments to ensure mem-brane saturation, thus preventing any exchange ofgases via the membrane in the upper part of theelectrolysis cell.

14 CHLOR-ALKALI PROCESS

INSTRUMENTATION

CA Process

Catalysis Vessel


� Visual Indication:Typically does not apply

� Continuous Level:E3 MODULEVELDisplacer-ActuatedTransmitter

� Point Level:Model A15Displacer-ActuatedLevel Switch

� Point Level:ECHOTEL Model 961Ultrasonic Switch orTHERMATEL ModelTD1/TD2 ThermalDispersion Switch

� Continuous Level:PULSAR Model RX5Pulse Burst RadarTransmitter or E3MODULEVELDisplacer-ActuatedTransmitter

10

Application: From Active Pharmaceutical Ingredients(APIs) to Vapor Phase Corrosion Inhibitors (VCIs),any one of a thousand additives and agents can beinjected into the process stream of a given industryto alter or impart new product properties or enhanceprocessing dynamics. Injection systems andchemical skid systems offer a wide range of dosingcontrol options.

Challenges: A chemical injection system typicallyconsists of one or more chemical supply tanks ordrums, a metering tank, a vessel with a mixer (ifrequired), a variable pump, and process controls.Chemical tanks and chemical skid packages requirelevel monitoring to ensure that the tanks do notoverfill or run out of feed chemicals.

15 CHEMICAL INJECTION

INSTRUMENTATION

Application: Highly purified water is essential inprocessing premium grade and highly purifiedproducts in the chemical, pharmaceutical, beverage,cosmetics and electronics industries. Deionization (DI)is frequently used to remove minerals from water bypassing water through two separate ion beds—cationand anion—followed by mixed bed saturation.

Challenges: Multiple bed DI units have pairs of tankswhere an optional CO2 degasser may be placed inbetween. Single bed DI units incorporate both thecation and anion exchangers mixed in a single tank.In addition to monitoring feed water, a level controlin the mixing tank will operate the transfer pump toroute the purified water to storage.

16 DEIONIZATION TANK

INSTRUMENTATION

Chemical Injection Skid


� Visual Indication:Atlas or AURORAMagnetic LevelIndicators canbe supplied withswitches ortransmitters

� Point Level:ECHOTEL Model961 UltrasonicSwitch; orTHERMATELModel TD1/TD2Switch

� Continuous Level:ECLIPSE Model 705Guided Wave Radar;or Enhanced JUPITERMagnetostrictive LevelTransmitter

� Continuous Level:PULSAR Model RX5Radar Transmitter; orECLIPSE Model 705Guided Wave RadarLevel Transmitter

� Point Level:ECHOTEL Model961 UltrasonicSwitch; or ModelT20 Float LevelSwitch

Deionization Tanks

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Application: Industrial chemical plants generate largevolumes of liquid wastes and runoffs that are collectedin large open-atmosphere sumps—concrete lift stations,in-ground pits or reservoirs. When the collected liquidreaches a pre-determined level it is discharged for trans-port to waste storage, treatment, or disposal facilities.

Challenges: Level controls typically actuate a pump toautomatically control sump level between two set points.The control can be configured to activate an alarm and apump shutdown to avoid overfill or pump cavitation inthe event of too high or too low levels. Sump levelcontrols must often be robust enough to contend withcorrosive media, high solids content and very punishingweather.

17 WASTE SUMP

INSTRUMENTATION

Application: To protect neighboring water systems,industrial wastewater must be neutralized so that it isneither acidic nor alkaline prior to its discharge. Theneutralization process takes place in a tank whereaqueous solutions of an acid and a baseare added to wastewater. Sulfuric acid, sodiumhydroxide and calcium carbonate are mostcommonly used.

Challenges: Level is measured in the neutralizationand chemical regeneration tanks which typicallyinvolve agitation and aggressive chemicals. Ideally,the tank level monitoring system should be easilyremovable for frequent cleaning. Contact levelsensors should be single rod types to avoid mediabuildup.

18 NEUTRALIZATION

INSTRUMENTATION

Open Atmosphere Sump

Neutralization Tank



� Visual Indication:Typically does notapply

� Continuous Level:ECHOTEL Model 338Ultrasonic Transmitter

� Point Level:ECHOTELModel 961UltrasonicLevel Switch

� Continuous Level:PULSAR Model RX5Pulse Burst RadarTransmitter orECHOTEL Model 338Ultrasonic Transmitter

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Application: Liquids stored at chemical plants includewater (potable, demineralized, fire, cooling), ingredientsand finished product storage. Hazardous chemicalsinclude inorganic acids, buffers, ammonia, chlorine,and solvents. Tanks range in size from small plastictotes to large steel tanks. The chemical stored andthe tank type largely determine the level control used.

Challenges: Level instruments indicate inventorylevels and protect against tank overfills and underfillsthat cavitate pumps. As some chemicals arecorrosive enough to destroy contact sensors, orcan crystallize and coat sensors to render themineffective, non-contact level monitoring, resistantmaterials, by-pass chambers and redundant controlsare sometimes used.

19 LIQUIDS STORAGE

INSTRUMENTATION

Application: Gases are frequently converted to a liquidto facilitate convenient storage. Many liquefy by coolingat normal atmospheric pressure while others requirepressurization as well. Industrial gases commonly storedin this fashion include liquid oxygen, liquid nitrogen, liq-uefied chlorine, LPG and LNG Gases are re-vaporizedthrough an application of heat.

Challenges: Above or below ground insulated storagetanks are built to specifically hold liquefied gases andminimize the amount of evaporation. Liquefied gas tanklevel monitoring typically contends with pressurization,extremely low temperatures and low dielectric media.Contact and non-contact measurement sensors mayrequire a standpipe.

20 LIQUEFIED GAS STORAGE

INSTRUMENTATION

Liquefied Gas Storage


� Continuous Level:ECLIPSE Model 705Guided Wave Radaror PULSAR Model RX5Pulse Burst RadarTransmitter

� Point Level:Series 3 Float-Actuated ExternalCage Switch orTUFFY II Float-Actuated Switch


� Continuous Level:PULSAR Model RX5 PulseBurst Radar Transmitteror ECHOTEL Model 338Transmitter

Field Storage


13

Application: The flow of air is monitored in nearly allindustrial settings, including applications for processing,air/gas mixing, cooling, blowing & drying, combustion,aeration, ventilation, filtration, and ingredients mixing.Compressed air (CA) is essential for pneumatic tools,materials handling, oxidation, fractionalization,cryogenics, dehydration, filtration and aeration.

Challenges: Significant air-flow variables include pipediameters, wide flow ranges, varying velocities and lowflow sensitivity. Flow meters help ensure efficient opera-tion at rated SCFM output and detect air leaks. A flowmeter with a totalizer provides an accurate measure-ment of CA consumption.

21 MASS AIR & COMPRESSED AIR FLOW

INSTRUMENTATION

Application: Common process gases used in chemical,pharmaceutical, plastics, semi-conductor, food, bever-age, and petrochemical processing include compressedair, natural gas, nitrogen, argon, hydrogen, oxygen andcarbon dioxide. Industrial waste exhaust gases arepresent in a wide variety of compositions from benignto toxic. Measurement of the flow of these later gasesis often required for reporting environmental emissions.

Challenges: Continuous mass flow measurement ofcompressed gases help improve plant efficiency. Oftenthese applications require high turndown capabilities andlow flow measurement with varying gas pressures andtemperatures. Thermal mass flow measurement ideallyhandles these applications providing high accuracy, highturndown with reliable, dependable operation.

22 PROCESS & WASTE GAS FLOW

INSTRUMENTATION

Combustion Air Flow

� Continuous Flow:THERMATEL Model TA2Thermal Dispersion MassFlow Meter

� Flow Alarm:THERMATELModel TD1/TD2Thermal DispersionFlow Switch

Flare Gas Monitoring



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Application: Nitrogen—the most widely used com-mercial gas—is the ideal tank blanketing gas wheninjected into the vapor space of a storage tank. Itprevents ignition of flammable liquids, inhibits vaporloss, and protects chemicals, pharmaceuticals andfoods from oxygen and moisture degradation.Nitrogen is also used as a purging agent and incryogenic applications.

Challenges: Mass flow measurement will monitor thenitrogen blanketing gas. A mass flow meter can trackusage as a cost control measure and determine thewhen, where and by whom of gas usage. Flow moni-toring of feed lines can prevent unsafe conditions thatmay arise when gas supply is insufficient.

23 TANK BLANKETING

INSTRUMENTATION

Application: Pumps are used throughout chemicaloperations for moving process fluids. Whether causedby a closed valve, a plugged line downstream or bypump cavitation, pumps operating in a reduced orno-flow condition can overheat and rupture the pump’sseal and cause a dangerous deviation in processpressure and temperature.

Challenges: A flow switch along a pump’s dischargepiping will actuate an alarm and shut down the pumpwhen liquid flow drops below the minimum flow rate.Solid state switches provide the highest level of protec-tion in these instances by offering low flow sensitivity,wide temperature operation and high turndown.

24 PUMP PROTECTION

INSTRUMENTATION

Field Tanks

Centrifugal Pumps

� Flow Alarm:THERMATEL ModelTD1/TD2 ThermalDispersion FlowSwitch

� Pump Protection:THERMATEL Model TD1/TD2Thermal Dispersion Flow Switch



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CORPORATE HEADQUARTERS705 Enterprise Street • Aurora, Illinois 60504-8149 USA

Phone: 630-969-4000 • Fax: 630-969-9489magnetrol.com • [email protected]

EUROPEAN HEADQUARTERSHeikensstraat 6 • 9240 Zele, Belgium

Phone: 052 45.11.11 • Fax: 052 45.09.93

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CANADA: 145 Jardin Drive, Units 1 & 2 • Concord, Ontario L4K 1X7

CHINA: Plant 6, No. 191, Huajin Road • Minhang District • Shanghai 201108

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Magnetrol & Magnetrol logotype, Aurora, Echotel, Eclipse, Jupiter, Modulevel,Pulsar, Thermatel, and Tuffy are registered trademarks of Magnetrol International, Incorporated.

Copyright © 2013 Magnetrol International, Incorporated. All rights reserved. Printed in the USA.

Bulletin: 41-178.1 • Effective: November 2008

AN INDUSTRY GUIDE TO LEVEL MEASUREMENT AND CONTROL FROM MAGNETROL

Other industry and special application brochures from MAGNETROL include:

• Crude Oil Processing• Flue Gas Desulfurization• Food & Beverage• Interface Level Measurement• Life Science• Mass Flow Measurement• Modular Skid Systems• Natural Gas Processing• Nuclear Power

• Petroleum Refining• Power Generation• Pulp & Paper Mills• Renewable Energy• Steam Generation• Tank Bridle Level Measurement• Tank Overfill Prevention• Understanding Safety Integrity Level (SIL)• Water & Wastewater

PLEASE NOTE: The instruments recommended in these brochures are based on field experience withsimilar applications and are included as a general guide to level and flow control selection. Becauseall applications differ, however, customers should determine suitability for their own purposes.

KONTAKTA OSS GÄRNA FÖR MER INFORMATION

Hugo Tillquist ABMejl: [email protected]: + 46 8 594 632 00

a guide to level and flow controls for the chemical industry industry.pdf · a guide to level and...

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