MeasurIT Flexim Wave Injector Refinery Brochure 0910

A Leap in Refinery Measuring Technology
______
Non-Intrusive
Flow Measurement up to 400°C
Using the WaveInjector ®
Reliable. Cost-Effective. Safe.
Sump measurement
(long/short resid)
______ 380 °C
Overflash measurement
______
Heavy gasoil (HGO)

______
Heavy vacuum gasoil (HVGO)

______
Cracker feeders
(thermal, catalytic, hydro)
______
Heat transfer oil

______
Measure from outside

what’s flowing inside.
______
47 °C
MeasurIT Technologies Ltd.

Craan, Craanford, email: info@measurIT.com Phone: +353 (0) 53 942 8962
Gorey, Co. Wexford, Ireland www.measurIT.com Fax: +353 (0) 53 942 8963
© Medienhaus Emsland GmbH & Co. KG.
When the Going Gets Hot, we Have the Best Solution:
The multitude of processes in a refinery Drawbacks of conventional

form a complex system of material and technologies
energy flows. From incoming crude to ______
outgoing products, everything is flowing Traditionally, orifice flowmeters,
– and for safe and efficient operation, Coriolis flowmeters and vortex flow-
these flows need to be measured. meters are used to measure refinery
flows. Especially in demanding environ-
Harsh process conditions can make ments, these well-know conventional
heavy demands on flowmeters, flowmeter types have equally well-known
however, especially at temperatures shortcomings:
between 200°C and 400°C.
– Intrusive sensors create pressure loss,
reducing process efficiency.
– Intrusive flow measurement technolo-

gies require frequent servicing. Sen-
sors in contact with hot and often dirty
hydrocarbons have high failure rates,
and pressure taps for orifice plates – In demanding refinery service, high
tend to clog. These high-maintenance maintenance costs critically undermine
measuring technologies reduce plant profitability, especially when the costs
availability. of reduced plant availability are taken
into account.
FLEXIM’s WaveInjector ® is simply a

better way to measure flow in refineries.
This robust non-contact measuring
technology is ideal for demanding
environments, as proven by its many
refinery installations worldwide.

WaveInjector ®
State-of-the-Art
Ultrasonic Technology for Flow
Measurement in Refineries.
Non-intrusive flow measurement gives Simple to install, reliable Unique measuring technology
you a competitive edge – in process performance ______
control, process management, and ______ FLEXIM is the only producer of high-
environmental protection. The ultrasonic transducers are simply temperature non-intrusive clamp-on
clamped to the outer surface of the flowmeter technology worldwide. The
FLEXIM’s WaveInjector ® has been pipe, using coupling plates for acoustic WaveInjector ® is used all over the world,
specially engineered for high-tempe- contact. There is no need to open the by some of the biggest names in the
rature applications. Using patented pipework, no drilling, and no break in process industries. The reason is clear:
technology, the WaveInjector ® thermally production. from crude oil to coal tar distillates,
separates the ultrasonic transducer WaveInjector ® remains accurate and
from the hot pipe, allowing operation Once installed, the transducers do not reliable under the toughest conditions.
at process temperatures up to 400°C. suffer wear and tear from the process
fluid, and they create no pressure drop.
The ATEX-certified transducers and
transmitters are safe and reliable in
potentially explosive atmospheres.
FLEXIM offers a wide range of ultrasonic

transducers and transmitters to match
any flow measurement application. The
exceptionally high dynamic range of
ultrasonic technology (0.01 to 25m/s)
out-performs most other flowmeter
types, bringing big advantages when
Reliable measuring technology, field-proven under
the toughest conditions in refinery applications you need to measure widely-varying
worldwide flowrates accurately.

At a Glance:
Advantages Trouble-free operation at high temperatures

of Clamp-On
No clogging, even with dirty or fouling fluids
Measurement
Using the No pressure loss
Patented Install and maintain without interrupting the process

WaveInjector ®
No extra risk of leaks
No pressure ports
Fits all standard pipe sizes from DN40 upwards
Certified for hazardous areas
Accurate and reproducible, even at very low flows
Wide dynamic range
Independent of medium conductivity and pressure
Works with flow in either direction

The Benefits Higher levels of operator and plant safety
to You
Improved plant availability
Better environmental compliance
Easier plant start-ups and upgrades
Higher profits thanks to tighter process control
Lower start-up, operating and maintenance costs
Lower inventory costs for flowmeters and spare parts
High application flexibility

On Site: Reliable Flow Measurement
with FLEXIM’s WaveInjector ®
Field-Proven Worldwide.
Concrete Benefits
___
... for the Flow Reliable non-intrusive
Measurement of Heat flow measurement
___
Transfer Oil at High Reliable process control
Temperatures ___
Easy retrofitting without opening the
pipe and without process interruption
___
No risk of toxic leak
In a Dutch refinery, a special heat Non-intrusive flow measurement with ___
transfer oil is used to supply process clamp-on transducers and WaveInjector ® No wear and tear – no process
heat for the distillation columns. The is a convenient and elegant solution to stoppage for inspection and
oil is heated up to 300°C and conveyed this measuring challenge. Since the maintenance
through a system of thermally insulated transducers do not come in contact ___
pipes to the columns. with the medium, there is no mechanical Higher plant availability
or chemical wear and tear. The meter ___
Effective operation of this installation can be also installed without opening Protection of health and environment
requires reliable flow measurement of the pipe, thus avoiding all risks of
the oil. Before non-intrusive ultrasonic potentially dangerous leaks. Ultrasonic
flow measurement technology was flow measurement thus offers the extra
introduced, the flow was determined advantages that it is environmentally
by means of differential pressure safe and improves plant safety and
measurement. Operations had to be efficiency.
stopped once a year in order to carry
out the inspection and maintenance
of the system. The medium is a car-
cinogenic substance. Therefore all
maintenance work required special
preparation and precautions.

Concrete Benefits
___
... for the Measurement Reliable, non-intrusive measurement
___
of Highly Viscous Coker
Easy upgrading without intrusion into the pipe
and Visbreaker Feed system and without process interruption
___
No risk of clogging of impulse piping
(unlike the former measuring system)
___
No production interruption for installation or
In a typical complex refinery operation, In a North American refinery, a differen- maintenance work
VAC tower residue or other high viscosity tial pressure measurement was replaced ___
liquid streams are fed into cokers and/ without any process interruption with the Reliable, maintenance free flow measurement
or visbreakers for further processing. non-intrusive WaveInjector ® , eliminating ___
The flow of these hot liquids (> 200 °C) daily maintenance tasks. Furthermore, Wide dynamic measurement range
is traditionally measured with differential the wide dynamic range of the FLUXUS
pressure devices (orifice or wedges) or turned out to be of additional advantage.
vortex meters. Previously 4 orifice plates were necessa-
ry to cover the entire measuring range.
Under the very severe process condi- Now a single instrument does the job.
tions, impulse line clogging and vortex
shedders breakdown are frequent. High
maintenance costs or even process
shut down are the consequences.
Fortuitously for the customer, this test

measurement revealed a control valve
... for Clamp-On failure.
Measurement The refinery now uses the flow values

of Bitumen at delivered by the WaveInjector ® for a
an Oil Sand Facility reliable mass balancing in the upgrader
process.
In a Canadian oil sand surface mine, differential pressure methods or Concrete Benefits
the recovered oil is refined directly on the vortex shedding meters. Like all inline ___
site. One of the many processing steps is measuring instruments, these were Reliable non-intrusive measurement
the thermal cracking. Optimally feeding subject to wear and tear and demanded ___
the upgraded bitumen into the thermal daily maintenance. Easy installation under problematic
cracker requires accurate monitoring conditions
and regulation of product input, which Non-intrusive flow measurement ___
can be accomplished only by reliable flow proved to be a significantly better Straight forward installation with no
measurement. Some flow meters are solution. A test measurement, using need to open the pipe and no downtime
also used for detection of line clogging the WaveInjector ® together with a port- ___
threat. Clogged lines can easily cause able transmitter on a 6" pipe carrying No corrosion and wear caused by the
a shutdown of the entire facility, leading hot VAC tower residue demonstrated medium, thus long operating life
to enormous downtime costs. In the past the superiority of ultrasonic technology.
such measurements were done with

Concrete Benefits
___
... for Overflash Reliable, non-intrusive measurement
___
Mass Flow
Measurement without any pressure
Measurement losses
at 380°C ___
Reliable measurement even
at very low flow velocities
___
Retrofitting and maintenance without
The overflash volume in atmospheric After successful testing, a flow interrupting plant operations
distillation is an important indicator measuring system using FLEXIM's ___
for effective and well balanced operation WaveInjector ® was installed at the Process optimization
of the distillation column. A precise measuring point, which is located in ___
measurement of this quantity poses a an ATEX 1 explosion hazard zone. The Easy upgrading without intrusion
special challenge. Driven only by gravity, installation was completed without any into the pipe system
the medium moves at very low flow modification to the existing system. ___
velocities of around 0.15m/s, with a Highly improved accuracy in
maximum flow rate of 10t/h. Therefore, The higher accuracy of the overflash comparison to conventional
in order to reach a reasonable accuracy, measurement now allows a drastic orifice meters
the previously installed orifice plates had improvement in process efficiency.
very small diameters. This resulted in a The investment costs were quickly
high pressure loss which could almost paid for by the higher yield.
not be overcome by the hydrostatic
conditions. Another challenge for the
measuring system was the high me-
dium temperature of around 380°C.

Concrete Benefits
___
... for the Measurement Easy upgrading without pipe work and
of Heavy Gasoil in without process stoppage
___
a Vacuum Destillation Reliable non-intrusive flow measurement
Tower ___
No influence on the process –
no pressure drop
___
Reliable measurement even at very low
In one of the most complex refineries In this case too, clamp-on flow measure- flow velocities
in Europe, replacement for an unreliable ment with a WaveInjector ® was the best ___
flow measurement system was sought. suited measuring technology. Due to the Retrofitting & maintenance without
The measuring point is located at the high dynamic range of the meter, even affecting the plant
heavy gas oil outlet of the vacuum small flows can be measured. Since ___
distillation tower, in an ATEX zone 1 the transducers are clamped onto the Process optimization
rated area. The gasoil flowing there pipe, the meter is not subject to wear ___
has a temperature of approximately and tear. Greater accuracy than conventional
300°C. orifice meters
measurement is possible, even with

large nominal pipe sizes. The robust
... for Clamp-On measuring system is not harmed by
either by hot steam purging or by short
Measurement of
term overheating.
Bitumen at 370°C
Concrete Benefits
___
Today, rising economic pressure is Intrusive flow meters face problems Reliable, non-intrusive, maintenance-
forcing major refineries to steadily inherent to their technologies: clogging free flow measurement
increase the throughput of their facili- of impulse piping, deposit formation, etc. ___
ties. Reliable flow measurement is These problems result in frequent No risk of clogging of impulse piping
crucial to the optimization of production shut-downs, high maintenance costs (unlike conventional measuring systems)
processes. Refined bitumen, which is and reduced throughput. ___
produced by means of vacuum distilla- No deposit formation, no parts subject to
tion at temperatures around 370°C, FLEXIM's answer to these problems wear and tear
poses a special challenge to flow is the non-intrusive WaveInjector ® – ___
measurement technology because ideally suited for high temperatures up No production interruption for installa-
of its high temperature and high to 400°C. There are no movable parts tion or maintenance work
viscosity. which could be subject to wear and tear. ___
There are no limitations to medium Simple, speedy installation,
pressure. Its installation will not require no pipe work
any down time. Accurate, drift-free

Concrete Benefits
___
... for Flow Measurement Reliable and low-maintenance flow
of Hot Pitch During the measurement
___
Distillation of Coal Tar No mechanical wear due to the
abrasive pitch
___
Reliable high temperature measurement
with the WaveInjector ®, not affected by
temperature shocks
In one of the world’s largest coal tar Flow measurement based on ultrasonic ___
refineries, the delivered raw material clamp-on procedure using the patented High measurement accuracy
is distilled to obtain technical oils and WaveInjector ® is a superior solution ___
aromatics, which serve as valuable basic to this problem. Based on convincing Excellent measuring dynamics
materials for the dye and pharmaceutical experience in tar distillation, wetted ___
industries. measuring systems in the entire plant No reduction of pipe size, no moving
are being replaced gradually by the parts, no pressure loss
Adverse process conditions and media non-intrusive FLUXUS ® ultrasonic ___
characteristics make flow measurement measuring systems. No leakage risk of the highly
of pitches a difficult task. Due to the high combustible and environmentally
solid content of the pitch, orifice plates dangerous medium
quickly lose their sharpness, and thus ___
their measuring accuracy. Furthermore, Simple installation and start-up of the
pressure impulse lines are quickly non-intrusive measuring system without
clogged by deposit formation. Due to work on pipes and down-time
thermal stress, Coriolis or Vortex flow ___
meters fail prematurely. Certified transducers and transmitters
for operation in hazardous areas

Concrete Benefits
___
... for the Flow Measurement Accurate non-intrusive flow
of Different Media, such measurement
___
as Tar, Machine Oils, Glycol
Quick installation and start-up of the
Mixes, Carbonate Lye, measuring equipment on the filled
Cracker Ethylene, Cooling pipeline, without process interruption.
Water, Hot Water, etc. ___
No risk of leakage
___
No wear due to the chemically
aggressive media
___
The Special Measuring Technology In all these cases, the experts reach High measuring accuracy, even under
Department of one of the leading for their FLEXIM measuring case: the unfavorable measuring conditions
producers of petrochemical products non-intrusive acoustic measuring ___
faces daily the most various challenges: technology offers maximum flexibility. Wide dynamic range assures precise
– control of permanently installed The ultrasonic transducers are simply measurements for low as well as high
measuring systems, clamped onto the pipe, they are quickly flow rates
– temporary replacement of defective installed, without cutting into pipe and ___
devices, without process interruption. For the One single measuring system for a
– flow measurement at places where many different applications, the depart- multitude of different applications
no stationary measuring system is ment uses a WaveInjector ® together with ___
installed, for diagnostic purposes or transducers selected for the respective Robust measuring system: solidly made
for process optimization. measuring task. The handy transmitter, transmitters, ultrasonic transducers and
easily fixed even at measuring points connection cables for use in humid and
with difficult access, automatically rough environments
recognizes the connected transducers. ___
More than 14 hours of battery-
powered measurement, display of
battery status
___
Complete measuring system in a
practical, sturdy transport case

FLEXIM’s WaveInjector ®
Non-intrusive flow The patented transducer mounting

measurement at extreme fixture realizes a long-term stable
temperatures clamp-on ultrasonic flow measurement
______ with standard temperature transducers
Ultrasonic flow measurement at high at temperatures as high as 400°C. It
temperatures was until now a trouble- offers all the well known advantages
some business: The gels or pads used of the clamp-on ultrasonic technology:
for acoustic coupling between the a non-intrusive measurement with a
transducers and the pipe have a limited wide dynamic range and a high flexibility.
temperature tolerance. Furthermore,
high temperatures accelerate the aging The WaveInjector ® is available in various
of the ultrasonic transducer’s piezo sizes, each of which covers a wide
elements and thus limit their useful nominal pipe diameter range. For big
operating life. pipes, special mounting chains ensure
a firm attachment to the pipe, thus
FLEXIM’s newly patented WaveInjector ® assuring high pressure on the coupling
overcomes these limitations. point.
Since the WaveInjector ® is a purely

mechanical device, it can be used in
explosion hazard areas without any
further certifications.
WaveInjector ® and ultrasonic transducers are installed without

interrupting the process

The WaveInjector ®
The WaveInjector ® is composed of the WaveInjector ®
coupling plate (1), the transducers clamping fixtures
(2), a pipe mounting clamp (3), together with an
acoustic coupling foil. The metallic coupling plate
between the transducer (4) and the pipe provides
nearly loss-free ultrasonic coupling. At the same
time, its cooling effect maintains a high temperature
gradient between the surface of the pipe and the
coupling surface of the transducer. This guarantees
that the maximum permissible transducer tempera-
ture is never exceeded.
The robust pipe mounting assembly (3) ensures a
high surface pressure between the coupling plates
and the pipe wall. Special metallic foils guarantee an
optimal long term stable acoustic coupling.
Temperature profile of the WaveInjector ®

The Future has Begun.
_______________________________________________________________________________________________________________________________
WaveInjector ® The WaveInjector ® is a special transducer mounting fixture
which makes it possible to use standard ultrasonic flow
transducers at extreme temperatures.
____________________________________________________________________________________________
Temperature range: -160 °C to 400 °C (-250 °F to 750 °F)
____________________________________________________________________________________________
Diameter range: 40 mm to 1000 mm (1.6 in to 39 in)
____________________________________________________________________________________________
Material: Stainless steel
____________________________________________________________________________________________
Hazardous area Since the WaveInjector ® is a purely mechanical device,
classification: it can be used without any further certification in explosion
hazard areas.
_______________________________________________________________________________________________________________________________
The transducers: All FLEXIM transducers are calibrated as a pair at the works.
The calibration can be traced back to national and internation-
al standards. The calibration data and the transducer parame-
ters are permanently stored in the transducers themselves.
An extended calibration can be carried out on demand.
____________________________________________________________________________________________
Operating temperature,
standard transducers: -40 °C to 130 °C (-40 °F to 266 °F)
____________________________________________________________________________________________
Operating temperature, high
temperature transducers: -30 °C to 200 °C (-22 °F to 392 °F)
____________________________________________________________________________________________
Operating temperature with
WaveInjector ®: up to 400 °C (750 °F)
____________________________________________________________________________________________
Degree of protection: IP65, IP67 or IP68 depending on type (EN60529); NEMA 4X
____________________________________________________________________________________________
Material: Stainless steel or PEEK with stainless steel protective cap
____________________________________________________________________________________________
Hazardous area
classification: FM Class I Div II and ATEX zone 1 & 2 types available
_______________________________________________________________________________________________________________________________

The matched FLUXUS ® flowmeters:
_______________________________________________________________________________________________________________________________
FLUXUS ® F601 The portable meter
____________________________________________________________________________________________
Operating temperature: -10 °C to 60 °C (14 °F to 140 °F)
____________________________________________________________________________________________
Flow channels: 2
____________________________________________________________________________________________
Degree of protection: Transmitter: IP65 gem. EN60529; NEMA 4X
Transport case: IP67 gem. EN60529; NEMA 4X
_______________________________________________________________________________________________________________________________
FLUXUS ® ADM 7407/7907 The multi-function meters
____________________________________________________________________________________________
Operating temperature: -10 °C to 60 °C (14 °F to 140 °F)
____________________________________________________________________________________________
Flow channels: 1 or 2
____________________________________________________________________________________________
Degree of protection ADM 7407: IP65; NEMA 4X
acc to EN60529: ADM 7907: IP20; NEMA 1
____________________________________________________________________________________________
Hazardous area
classification: ADM 7407: ATEX zone 2 or FM Class I Div II optional
_______________________________________________________________________________________________________________________________
FLUXUS ® ADM 8027/8127 The explosion-proof experts
____________________________________________________________________________________________
Operating temperature: ADM 8027: -20 °C to 60 °C (14 °F to 140 °F)
ADM 8127: -20 °C to 50 °C (14 °F to 122 °F)
____________________________________________________________________________________________
Flow channels: 1 or 2
____________________________________________________________________________________________
Degree of protection: IP66 acc. to EN60529
____________________________________________________________________________________________
Hazardous area
classification: ATEX zones 1 or 2
_______________________________________________________________________________________________________________________________

FLEXIM
A short portrait
For nearly 20 years now, FLEXIM has Competent and professional associates
been an active leader in many areas of in our sales offices and regional head-
process instrumentation in both national quarters in Europe, North America,
and international markets. In addition to Asia and all over the world ensure the
non-intrusive flow measurement, FLEXIM worldwide distribution of FLEXIM’s proven
specializes in innovative online process technology and guarantee you qualified
analysis using ultrasonic technology and service.
refractometry.
Year after year, FLEXIM continues its

substantial investment in research and
development in order to maintain and
further improve its position as an industry
leader. In addition, FLEXIM maintains a
close contact to its customers. Innovative
and reliable products meeting exactly the
needs of the customer are the result.
BUREFINERYV2-1EN Subject to change without notification. 2009/06


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A Leap in Refinery Measuring Technology

Heavy gasoil (HGO)

Heavy vacuum gasoil (HVGO)

Heat transfer oil

Measure from outside

MeasurIT Technologies Ltd.

When the Going Gets Hot, we Have the Best Solution:

The multitude of processes in a refinery Drawbacks of conventional

– Intrusive flow measurement technolo-

FLEXIM’s WaveInjector ® is simply a

MeasurIT Technologies Ltd.

FLEXIM offers a wide range of ultrasonic

MeasurIT Technologies Ltd.

Advantages Trouble-free operation at high temperatures

Patented Install and maintain without interrupting the process

Fits all standard pipe sizes from DN40 upwards

Certified for hazardous areas

Accurate and reproducible, even at very low flows

Wide dynamic range

Independent of medium conductivity and pressure

Works with flow in either direction

MeasurIT Technologies Ltd.

Better environmental compliance

Easier plant start-ups and upgrades

Higher profits thanks to tighter process control

Lower start-up, operating and maintenance costs

Lower inventory costs for flowmeters and spare parts

High application flexibility

MeasurIT Technologies Ltd.

MeasurIT Technologies Ltd.

Fortuitously for the customer, this test

Measurement The refinery now uses the flow values

MeasurIT Technologies Ltd.

MeasurIT Technologies Ltd.

measurement is possible, even with

MeasurIT Technologies Ltd.

MeasurIT Technologies Ltd.

MeasurIT Technologies Ltd.

Non-intrusive flow The patented transducer mounting

Since the WaveInjector ® is a purely

WaveInjector ® and ultrasonic transducers are installed without

MeasurIT Technologies Ltd.

Temperature profile of the WaveInjector ®

MeasurIT Technologies Ltd.

MeasurIT Technologies Ltd.

MeasurIT Technologies Ltd.

Year after year, FLEXIM continues its

MeasurIT Technologies Ltd.

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