IBP1654_12 FROM TAP TO TRANSMITTER MEASUREMENTACCURACY RELIES ON QUALITY OF THE WHOLE INSTRUMENTATION SYSTEM Sam Johnson1, Diego Copertari

2, Jean Strasse3

Copyright 2012, Brazilian Petroleum, Gas and Biofuels Institute - IBP

This Technical Paper was prepared for presentation at the Rio Oi & Gas Expo and Conference 2012, held between September, 1720, 2012, in Rio de Janeiro. This Technical Paper was selected for presentation by the Technical Committee of the event according to the information contained in the final paper submitted by the author(s). The organizers are not supposed to translate or correct the submitted papers. The material as it is presented, does not necessarily represent Brazilian Petroleum, Gas and Biofuels Institute opinion, or that of its Members or Representatives. Authors consent to the publication of this Technical Paper in the Rio Oil & Gas Expo and Conference 2012 Proceedings.

Resumo
Atualmente as indstrias de processo, incluindo qumica e petroqumica, refino, leo e gs e papel e celulose so confrontadas com o aumento das despesas operacionais, reduo da fora de trabalho, forte concorrncia e a ampla necessidade de se fazer mais com menos. Para atender a esta demanda, muitas empresas esto fazendo uso dos avanos em controle e instrumentao a fim de otimizar o desempenho de sua planta. Muitos desses avanos se encontram na melhora de componentes eletrnicos, que fornecem uma maior preciso nas medies e algoritmos de controle mais rpidos, que por sua vez permitem uma maior produo e maiores rendimentos dos produtos especificados (menos resduos e/ou retrabalho). Como qualquer princpio de medio, a qualidade da sada e por isso, a correta preciso da medio, depende da qualidade da entrada no instrumento de medio. Muitos profissionais de instrumentao focam sua ateno nos avanos da tecnologia dos eletrnicos ao invs de focar na qualidade dos componentes de manipulao de fluidos e nas conexes que ligam a instrumentao ao processo. No entanto, um sistema de instrumentao uma rede de componentes e informaes. Os componentes do sistema de fluido que ligam o ponto de tomada da amostra at o transmissor so crticos para uma medio precisa e deveriam ser considerados na implantao de uma nova instalao do transmissor de presso diferencial. Este artigo ir analisar a integridade do sistema (vazamento), consideraes de instrumentos especficos, conectando a tomada de amostra ao transmissor, a selecionando e instalando o transmissor e outras consideraes importantes para o projeto e a instalao da tomada de amostra para o transmissor do sistema.

Abstract
Today processing industries, including chemical and petrochemical, refining, oil and gas, and pulp and paper, are faced with increased operating expenses, reductions in labor forces, strong competition, and an overall need to do more with less. To meet these demands, many companies are making use of advances in instrumentation and control technologies to optimize plant performance. Many of these advances lie in improved electronic components that provide improved accuracy of measurements and faster control algorithms, which in turn allow for increased throughput and greater yields of on-spec product (less waste and/or rework). As with any measurement principle, however, the quality of the output, and hence the true accuracy of the measurement, relies on the quality of the input to the measuring device. Many instrumentation professionals focus their attention on the electronic advances in technology rather than on the quality of the fluid handling components and connections that link the instrumentation to the process. However, an instrumentation system is a network of devices and components, each intended to perform a specific function so that the system will provide the required data. The fluid system components that link the tap to the transmitter are critical for accurate measurement and should be considered when deploying new pressure and differential pressure transmitter installations. This article will review system integrity (leakage), specific instrument considerations, connecting the tap to the transmitter, selecting and installing a transmitter and additional issues important to the design and installation of tapto-transmitter systems.

______________________________ 1 Bachelor's Degree in History, Process Instrumentation Product Manager Swagelok Company 2 Masters Degree in Engineering Business Development Manager Swagelok Company 3 Advertising person, Marketing Assistant Swagelok Brasil

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1. Introduction
Processing industries, including chemical and petrochemical, refining, oil and gas, and pulp and paper, today are faced with increased operating expenses, reductions in the number of qualified workers, strong competition and the need to do more with less. To meet these challenges, many companies are making use of advances in instrumentation and control technologies to optimize plant performance. These advances often lie in improved electronic components that provide improved accuracy of measurements and faster control algorithms, which in turn allow for increased throughput and greater yields of on-spec product. As with any measurement principle, however, the quality of the output and the true reliability of the measurement are dependent on the quality of the input to the measuring device. From the fluid-tight functioning of the process interface valve, to the leak-tight threadless connections and temperature-maintaining properties of the impulse lines, to the high-integrity shutoff of the manifold, fluid-handling components in instrumentation hook-up could be considered the most critical severe-service applications in the plant. The process instrumentation linefrom tap to transmitter is a network of devices and components, each intended to perform a specific function (Figure 1). The line must work as a single unit and not just a collection of components. Any single component working improperly can corrupt the system and the data, potentially resulting in loss of system fluid, out-of-spec production and downtime expenses.

Figure 1. Process Instrumentation Line For designers and engineers in the process industry, technological advancements have made transmitters a more valuable component than ever. While taking the necessary time to evaluate and choose transmitters, engineers must also remember that a reliable measurement depends on the complete line. The basis of a well-functioning unit, and its positive influence on a facilitys bottom line, is the proper selection of fluid-handling components. Not paying careful attention to these components means risking your considerable investment in the transmitter and makes it more likely that your system and data are corrupt. It cant be overstated: A systems measurement is only as good as the sum total of its components. Select each one with care.

2. Process Interface Valve

The process interface valve (PIV), or sample tap, is the first valve off the process line. Historically, the PIV of choice has been the gate valve, a single, multi-turn valve built with an outside screw and yoke configuration to allow for repacking of the valve while its in service. Gate valves continue to be manufactured and remain widely used today, due in large part to their legacy status. However, because of inherent limitations in a single-block valve, customers are moving away from this single isolation valve to a newer class of PIV: the double block and bleed (DBB) configuration. Consisting of two isolationor blockvalves with a bleed valve in between, the DBB configuration makes systems safer by eliminating the possibility of pressure build-up to the transmitter during maintenance. With a single gate valve, leakage canand often doesoccur, leading to the build up of pressure. During normal operation, the 2

Rio Oil & Gas Expo and Conference 2012 DBBs two isolation valves are open and the bleed valve is closed, allowing the transmitter to sense pressure fluctuations and, therefore, measure variable pressure When being serviced, however, the transmitter must contain no pressure. Achieving zero pressure at the transmitter is typically accomplished by using an instrument manifold to isolate the transmitter from line pressure. However, when it is necessary to service the manifold or the impulse lines, a DBB process interface valve can be the best solution. The maintenance process is started by connecting a drain tube to the DBBs bleed valve. The other end of the tube is inserted into a receptacle. A technician closes the first isolation valve, the one nearest to the process line, and then opens the bleed valve. Line pressure vents back through the already open second isolation valve, out the bleed valves drain tube, and into the receptacle, providing the important added benefit of ensuring that no fluid escapes to the environment. The second isolation valve is then closed to guarantee zero pressure in the impulse line. If the first isolation valve were to leak, the second valve would contain any fluid and force it to drain through the open bleed valve. This redundancy of containment is an important safety consideration for technicians servicing instrument line components. Service personnel safety depends on no unexpected build-up of pressure. For maximum safety when servicing the transmitter, use both the manifold and the DBB to achieve zero pressure. Although double block and bleed valves can be constructed with three separate valves, the advent of the compact DBB has changed the process instrumentation landscape. The compact DBB contains all three valves in a single, self-contained unit. In addition to providing a leak-tight connection and enhanced safety, compact DBB valves offer distinct advantages over their separately constructed counterparts (Figure 2):

Figure 2. Traditional 3-Valve to VB04 Double Block-Bleed Comparison Fewer leak points; Flexibility to configure the product using different size orifices and flanged connections; Reduced size and weight, reducing the need for and expense of structural support of the instrumentation system; Reduced cost; Faster and easier to install; Available in a wide range of pressure classes and materials for compatibility with specific piping system designs; and Designed and tested for fire safety. 3

Rio Oil & Gas Expo and Conference 2012 Originated in the 1980s by British engineers working in the offshore industry in the North Sea, compact DBB valves evolved from the need to reduce the size and weight of the three-valve configuration and reduce the number of leak paths. The technology is migrating onshore because the advantages it offers are also prized in on- shore applications. Europe has begun to embrace the technology, as has the Asia-Pacific region. The United States, where the gate valve continues to dominate, has been slower to adopt the DBB technology. The opportunities are great for American companies to benefit from the newest generation of process interface valves.

3. Ball and Needle Valves

In the classic compact DBB, the two isolation valves are ball valves and the bleed valve is a needle valve. The large orifices of the ball valves reduce the potential for plugging and make the configuration more effective for higher viscosity fluids. For this reason, the classic DBB is increasingly being employed in upstream environments, such as in oil and gas exploration. By comparison, the monoflange, a second kind of compact DBB, is the most compact double block and bleed available, offering three needle valves in a single flange. With their smaller orifices, needle valves are better for lighter, less viscous fluids and hydrocarbons. Monoflanges, then, are best sourced downstream, such as in chemical and refining industries. The best DBB valves, built with high-integrity seals requiring minimum maintenance, resist leaks to the atmosphere and across the seat. Several technologies are available for the ball and needle valves making up a DBB: One such needle-valve technology features a ball stem tip that does not rotate upon closure. In this case, the ball stem tip is free to rotate in all planes rather than being forced to turn with the valve stem. When a ball tip turns with the stem as with a stationary ball tip, which is built as a single unit with the stem the ball can grind down and score the valve seat. Scoring the seat damages it and, upon repeated engagements, typically results in leaks. By contrast, because the ball stem tip does not rotate as it engages the seat of the valve; it preserves the integrity of the seat. Some non-rotating or controlled ball tips take the technology of a needle valve a step further. A typical ball is a spherical ball that rotates in all planes and is considered uncontrolled. Every time the ball engages the valve seat, the ball is left with a line seal, a scored indentation that encircles the surface of the ball. Because the ball floats in all planes, a different surface area engages the seat each time the valve is closed and results in a number of crisscrossing line seals on the surface of the ball. The integrity of the valve is compromised at the intersection points of the line seals, a condition known as loss of line seal. If the ball tip could be limited to a single line seal, which would engage the seat each time the valve is closed, the line seal would no longer be lost. Controlled ball tips achieve this result. Controlled tips are spherical except for one flattened surface at the top of the sphere. The flattened surface limits rotation to only one plane, around a central axis. The result is a best-in-class valve, offering customers a consistent line seal and repetitive, leak-tight shut-off. Another trait to specify in a needle valve is packing located below the threads, so that the system media, when the valve is open, cant reach the threads and corrode or clog them. Look also for threads that are workhardened, or cold-rolled, for high strength, smooth operation, and long life. In addition, high-quality needle valves are built with a two-piece knuckle joint located above the packing and therefore out of reach of the system media. This design provides a non-rotating needle feature. Like the controlled, non-rotational ball tip, the non-rotational needle tip, or Vee tip, doesnt turn with the stem and grind damagingly into the seat. Instead, the Vee tip moves only axially, up and down. It seats properly and consistently, providing the highest-integrity seal. In summary, non-rotational needle Vee tips and controlled, non-rotational ball tips represent the best choices when specifying DBB needle valves. As with needle valves, new technologies are offering better choices in the selection of ball valves. For example, advancements are being made in seat designs for ball valvesspecifically, in the methods used to apply pressure to the seat. The seals in ball valves may be generated by the force of the fluid stream against the ball. Additional force, however, may be needed to compensate for temperature and pressure variations. This force comes from added components used in the seat design. One force-creating method is the energizedor live-loadedseat. The energized seat design employs either a spring-loaded seat or a spring or O-ring inserted between the end screw and the seat. In the case of high system pressure, the ball is forced downstream, flexing the downstream seat and creating a seal. Under low system pressure, the energized seat compensates for system pressure by pushing against the ball to create a seal. A second advancement in DBB ball valves is the live-loaded stem seal, also known as a lip seal. In this design, a spring within a PTFE container takes the place of traditional stem packing, which can wear over time. The spring is continuously providing a lateral force, which maintains a positive seal against the stem, an important consideration in situations with low system pressure. Other benefits are less operating torque required, improved performance, and compensation for packing wear. 4

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4. Impulse Lines and Fittings

A vital part of the instrumentation loop, impulse lines connect the process interface valve to the transmitter. Ideally, impulse lines convey the process conditions to the transmitter without allowing for changes in the process fluid. Changes in the fluid can cause a bias that leads to erroneous measurements. Impulse lines typically require insulation both to ensure that process temperatures are maintained as well as to protect against freezing. Warm fluid that cools in the impulse line can lead to condensation, which compromises measurements and necessitates increased maintenance. One way to insulate impulse lines to maintain fluid temperature is known as field tracing. A laborious, time consuming, and costly process done on the facility site, field tracing involves manually insulating the impulse line, and typically lagging it, or covering it with a protective shell. Sometimes field tracing also involves running a steam line next to the impulse line or wrapping electrical heat tapeor tracearound the line. Compared with field tracing, pre-insulated bundled tubing is a predictable, repeatable, low-cost, and easily maintained solution for instrumentation applications that require process fluid freeze protection, temperature maintenance, and energy conservation. The pre-insulated tubing can be installed more quickly and delivers more consistent thermal performance than field traced and insulated systems. These products contain the proper number of tubing runs wrapped in insulation and encased in a rugged polymeric jacket. The tube bundles can be actively heated, or left unheated, and are available with accessories to prevent moisture from wicking in from the ends. Additionally, bundled tubing is available in coiled lengths, which eliminates the number of mechanical connections. Reducing the number of connections on impulse lines is advantageous, because fewer connections mean fewer opportunities for leaks. As with valves, leakage to atmosphere from a fitting connection is a key compromising factor in the accuracy of a process instrument loop. In addition to wasting thousands of dollars each year, leaks impair the transmitters ability to report accurate and representative process data, such as pressure, flow, and level. Where tube fitting connections must be installed, choosing the highest quality component is essential. Tube fitting technology has evolved. A two-ferrule fitting option is the design of choice; the front ferrule performs the sealing function, while the back ferrule grips or holds the tube. However, not all two-ferrule fittings are created equal. Available designs employ various methods of gripping onto the tubing, including one that bites into the skin of the tubing weakening its ability to holdand another that grips and holds the tubing across a long area. The grip of a bite-type ferrule delivers primarily an indentation in the tubing. This indentation can result in a less than fully supported stress riser that can weaken the tube grip and lead to failure if the connection is exposed to vibration. The ideal two-ferrule fitting connection is one that also delivers a deliberate hinging-colleting (non-bowing) action. This more direct ferrule-to-tube contact and gripping support directly behind the ferrule indentation enhances the tube grip reliability. It also reduces the effects of vibration on or increases the vibration endurance limit of the tube fitting connection. These smallest of components can make or break the accuracy of your measurement. System designers who choose tube fittings wisely have taken an important step toward a leak-tight instrumentation line.

5. Manifolds
Up to this point in the instrumentation line, everything affecting the performance of the measurement has been associated with leakage. In addition, the manifold itself can directly affect the quality of the measurement. As such, the manifold is one of the most critical elements in the instrumentation loop, yet poor manufacturing practices and insufficient quality control measures can produce an inferior manifold. For example, burrs and other manufacturing debris may prevent proper isolation of the manifold valves and lead to poor calibrations and, thus, false readings. Advanced manufacturing processes, such as thermal deburring and 100 percent testing, increase a users confidence that the component is a high-integrity, severe-service valve adding significant value to a process instrumentation investment. For a standard differential pressure (DP) transmitter, a three-valve manifold provides isolation and equalization valve functions to enable proper field calibration (Figure 3). As with the process interface valve, sealing integrity of the manifold is essential.

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Figure 3. Manifold The two isolation valves and single equalization valve in a manifold are needle valves. Normally open, the isolation valves are closed during calibration. Typically closed, the equalization valve is opened during calibration. This procedure results in the transmitter being zeroed out, under no pressure, and calibrated. After calibration, the equalization valve is closed again and the isolation valves opened. If the equalization valve allows leakage across the seat at this point, high pressure bleeds over into the low pressure line. The result is an erroneous differential pressure measurement and, in turn, compromised flow control. A small leak in this one manifold valve can, by itself, negate the technological advancements for which the transmitter was selected. Facility owners are therefore encouraged to source manifolds that contain needle valves having the qualities described earlier, specifically a non-rotational needle tip or controlled ball-tip design.

6. Transmitter
Transmitters generate the electronic signal that provides input to the control system. Modern transmitters are available in many different electronic configurations, such as standard analog outputs (4 to 20mA), overlaid digital output signals (HART), and fieldbus devices. The proper transmitter is the device that integrates smoothly into the control scheme for the given application. While fieldbus devices have gained much attention in recent years, standard analog control schemes still predominate in the processing industry today. The standard 4 to 20 milliamp transmitter supplies representative data on the state of the process, is easily joined with the control system, and requires little, if any, customization (I/O cards, for example). HART-enabled transmitters add functionality by delivering secondary process variable information such as diagnostic and historical maintenance along with the primary process variable information. Transmitters that are HART-enabled typically require specialized I/O in order for the overlaid digital information to be used by the control system. The advanced features of HART allow the user to gain many of the advantages that digital communication protocols allow while being compatible with traditional 4 to 20 milliamp installations. Fieldbus-based transmitters utilize a true digital communication protocol that eliminates the need for individual twisted-pair home runs between the transmitter and the control system. With their ability to communicate directly between one another and among other fieldbus-based components, these devices help reduce the amount of wiring associated with instrumentation hook-up. In addition to advanced functionality similar to that offered by HART, fieldbus installations offer the benefit of reduced installation costs, diagnostics and remote interrogation, and peer-to-peer control capabilities. Proper installation of the transmitter is vital. Facility owners should consider those site and application details that can compromise performance. Factors to weigh are vibration, temperature, and the ability to access the device. Some traditional transmitter/manifold mounting brackets can loosen and transfer the weight of the entire instrument assembly to the instrument connection. An effective solution is to employ the concept of a threadless instrument loop 6

Rio Oil & Gas Expo and Conference 2012 and a robust transmitter mounting designed to reduce the effects of vibration. You can realize all the benefits of your investment when you can minimize the threaded connections in your instrument loop. 6.1 Supplier Considerations Facility owners gain an advantage when choosing suppliers that offer specialized services, such as: A complete instrument hook-up in a kit, from tap to transmitter: the process interface valve, bundled tubing, the manifold and transmitter unit, and fittings; Computer-Aided Design (CAD) templates that can be merged directly into the users electronic design system to aid in the layout of fluid-system assemblies and instrumentation hook-ups. CAD templates offer speed, convenience, and cost savings; Sales and service centers with full services located in the region; and Installation training tailored to individual users, designed to improve the safety of the work environment, increase productivity, and help facility personnel stay abreast of the latest fluid system technologies.

7. Conclusion
In todays increasingly competitive and challenging environment for process industries, a well-functioning process instrumentation line is a necessity. While transmitters are a key part of the system, designers and engineers need to understand that the quality of the measurement depends equally on the fluid-handling components in the hook-up. The process interface valve, the impulse lines and fittings, and the manifold must be chosen carefully, as they produce the input that the transmitter relies on to make its measurements. From tap to transmitter, the process instrumentation line directly affects a facilitys profitability.