Industrial Pressure Gauges with Acid Leak Detection Technology

In the chemical manufacturing and processing world, the instrumentation and tools used in the industry need to be of the highest quality and withstand harsh operating conditions. These instruments, which are often directly exposed to chemical processes, must endure exposure to extreme temperatures, corrosive substances, and other aggressive conditions. One of the vital instruments in the chemical industry is the industrial pressure gauge, a device used to measure and monitor the pressure of fluids and gases in pipelines, vessels, and other industrial systems. Given the significance of accurate pressure measurement, integrating acid leak detection (ALD) technology into these pressure gauges has become increasingly important. Acid leak detection assemblies offer a valuable tool for industry professionals, providing a visual indication of changes in process media, as they utilize a special coating that changes color when exposed to compounds with pH levels of ≤3.0.

Need for Acid Leak Detection in Pressure Gauges

Industrial pressure gauges are vital for monitoring and controlling processes in various industries, particularly the chemical industry, where accurate pressure readings ensure product quality, safety, and compliance with regulations. As many chemical processes involve acidic substances, a leak of corrosive acids can have serious consequences. Not only can it damage equipment and result in costly downtime, but it can also pose serious safety risks to workers and the environment.

Acid leak detection technology plays an essential role in mitigating these risks. By incorporating this technology into industrial pressure gauges, it is possible to quickly detect leaks of acidic compounds and take appropriate action to prevent damage and ensure safety.

How ALD Technology Works in Pressure Gauges

The ALD technology is a special coating applied to parts of the pressure gauge that might come in contact with the process media in the event of a leak. This coating changes color when exposed to compounds with pH levels of ≤3.0, making it an effective tool for detecting acidic leaks.

The color change in the coating is usually irreversible, which allows for easy identification of leaks even after the fact. Once the gauge shows evidence of a color change, it indicates that an acid leak has occurred, and maintenance personnel can take appropriate measures to address the issue.

Pressure gauges equipped with ALD technology are installed in critical areas of chemical plants, refineries, and other industrial facilities with a high potential for acid leaks. 

They monitor pressure in pipelines, tanks, reactors, and other equipment where corrosive substances are processed or stored.

Advantages of ALD Technology in Pressure Gauges

• Early Detection: ALD technology allows for the early detection of acid leaks, preventing further damage to equipment and reducing the risk of accidents.
• Visual Indication: The color change clearly indicates a leak, making it easier for operators to identify the issue and take corrective action.
• Enhanced Safety: By detecting leaks early, ALD technology helps to improve the safety of workers and the environment.
• Cost Savings: Early detection of acid leaks can reduce downtime and repair costs, leading to cost savings for the facility.

Conclusion

Incorporating acid leak detection technology into industrial pressure gauges is an effective way to enhance the safety and efficiency of chemical processes. The ALD technology visually indicates changes in process media, helping operators quickly identify and address leaks of acidic compounds. This technology not only improves the facility's overall safety but also reduces the risk of costly equipment damage and downtime.

Mead O'Brien

https://meadobrien.com

(800) 874-9655

The Role of Industrial Diaphragm Seals

Diaphragm seals protect industrial pressure gauges, transmitters, and other instruments in corrosive, high-temperature, and high-vibration applications for the following reasons:

1. Protection against corrosive media: Diaphragm seals isolate the gauge from corrosive liquids and gases, preventing damage to the indicator and ensuring accurate readings.
2. High-temperature resistance: Diaphragm seals use materials that can withstand high temperatures, such as PTFE and Monel, allowing the application of the gauge in high-temperature applications without affecting accuracy.
3. Vibration resistance: In high-vibration applications, diaphragm seals reduce the vibration transfer to the gauge, reducing the risk of damage and ensuring accuracy.
4. Media compatibility: The diaphragm material can be selected based on compatibility with the process media, ensuring accurate readings and preventing damage to the gauge.
5. Longer service life: A diaphragm seal with a pressure gauge in corrosive, high-temperature, and high-vibration applications can extend the service life of the pressure gauge, reducing the need for maintenance and replacements.

Diaphragm seals transfer movement to pressure sensors through mechanical means. A flexible diaphragm is attached to the gauge's sensor and is separated from the process fluid by a filled chamber or a static pressure-transmitting liquid. As the process pressure changes, it causes the diaphragm to flex and transfer the movement to the gauge's sensor, which translates to the pressure reading.

Industrial diaphragm seals provide the "wetted" interface. Wetted refers to the parts of a diaphragm seal that come into contact with the measured process fluid. In industrial diaphragm seals, the wetted components consist of the diaphragm and the metal or ceramic components surrounding the diaphragm and are in direct contact with the process fluid. These parts must be compatible with the process media and withstand the fluid's corrosive and abrasive properties.

In conclusion, diaphragm seals provide a protective interface between the process media and the pressure gauge that ensures protection, accuracy, and increased longevity in challenging industrial applications, making them essential for industrial pressure gauges.

For more information, contact Mead O'Brien. Call (800) 874-9655 or visit https://meadobrien.com.

The Ashcroft Acid Leak Detection Assembly

While dangerous acids have been safely used in industrial applications for many years, specifying proper pressure instrumentation for these locations requires unique expertise. Ashcroft understands the dangers of acid leaks. That is why they developed the Acid Leak Detection (ALD) assembly.

ALD is a special yellow coating that changes to red once it is exposed to acids with a pH of ≤ 3.0, providing visual indication of a leak of process media. 

For more information about the Ashcroft Acid Leak Detection system, contact Mead O'Brien. Call them at (800) 892-2769 or visit their website at https://meadobrien.com​.

The Ashcroft E2 Sanitary Pressure Transmitter

The Ashcroft® E2 sanitary pressure transmitter integrates established thin film sensor technology while delivering sanitary benefits by using a tri-clamp fitting with an isolation seal. This model is designed to maintain process integrity and is an excellent option for sanitary applications, including those requiring 3A approval or requiring challenging process monitoring and control. The broad option of electrical connections and filling fluids satisfies specific application requirements.

Ashcroft E2 Sanitary Pressure Transmitter

Key Features:

• Available with 1.5" and 2.0" Tri-Clamp® connection
• 3A approved
• Wide selection of electrical terminations
• Customized configurations
• External magnetic offset and span adjustment

Specifications:

• Accuracy: ±0.25%, ±0.5% or ±1.00% of span
• Process Connection: 316L stainless steel
• Pressure Range: vacuum to 1,000 psi
• Ingress Rating: IP66, IP67 or IP69K (consult factory)
• Surface Finish: 12 to 20 Ra electropolished diaphragm 

DOWNLOAD THE ASHCROFT E2 BROCHURE HERE

For more information, call Mead O'Brien now at (800) 892-2769 or visit their website at https://meadobrien.com.

Understanding Differential Pressure Measurement: Differential Pressure Gauge Example

This video (courtesy of Ashcroft) does an outstanding job illustrating the concepts of differential pressure and flow measurement using the differential pressure method.

Engineered restriction devices are often inserted into a closed pipe system to create a differential pressure for the purposes of measuring fluid flow rate. These restrictions can come in the form of an orifice plates, Venturi, wedge, and other designs.

To measure the differential pressure, taps must be installed on both sides of the plate.  The upstream side will always produce the greater pressure, and is referred to as the high side. Conversely, the downstream pressure will always be the lesser value, due to the obstruction.

A differential pressure gauge's range is based on the maximum difference that can be expected as a result of the restriction. The gauge's dial will display the differential pressure in units of pressure measurement, like psi or bar.  By applying the linear square root relationship between flow rate and pressure, the gauge style can be scaled in a specified rate of flow, such as gallons per minute. A dual scale dial can also be created to display both the flow rate and the differential pressure.

Another important consideration is the maximum line pressure, also referred to as the static pressure. The higher the static pressure, the more robust the gauge must be to contain it. That's why it's crucial to ensure that the gauge carries a static pressure rating that exceeds the highest pressure in the line.

For more information about differential pressure gauges, transmitters, and flow measurement, contact Mead O'Brien at (800) 892-2769 or visit their web site at https://meadobrien.com.

Calibration Procedures for the Ashcroft P-Series Snap Action Switch Pressure Control

The Ashcroft P Series pressure control is a precision device which features a snap action switch. Fixed deadband is available with single or dual SPDT independently adjustable switches with various electrical ratings. Adjustable deadband is available with a SPDT switch with various electrical ratings. Several wetted material constructions for compatibility with pressure media may be obtained.

The “P” Series Ashcroft snap action pressure switch is available in explosion-proof NEMA 7 & 9 configurations. The enclosure is an epoxy coated aluminum casting.

This video describes how to calibrate the Ashcroft P-Series.

For more information about Ashcroft, Inc. products, contact:
Mead O'Brien
https://meadobrien.com
(800) 892-2769

NACE Standards - Measuring the Pressure of Sour Gas and Crude

In 1943 a group of corrosion engineers working in the pipeline industry formed the National Association of Corrosion Engineers with the goal of "protecting people, assets, and the environment from corrosion”. In the 1960s, they commenced development of control standards to define appropriate materials for a wide variety of corrosive applications, including oil and gas production and refinery facilities. In 1993, the organization was renamed “NACE International”.

Today, NACE offers over 150 standards that address metal corrosion in a vast number of applications ranging from exposed metal structures to corrosion resistant coatings on railroad cars.

The following NACE Measuring Pressure of Sour Gas and Crude White Paper (courtesy of Ashcroft) discusses NACE standards that specifically address corrosion resulting from expo- sure to sour gas or sour crude.

You can download the entire NACE Standards Sour Gas and Crude White Paper here, or review it in the embedded document below.

For more information, contact Mead O'Brien at (800) 892-2769 or visit their web site at https://meadobrien.com.

NACE Standards - Measuring the Pressure of Sour Gas and Crude from Mead O'Brien, Inc.

Industrial Thermowells: Sometimes Taken for Granted, but Critically Important

Thermowells come in a wide variety
of shapes, materials, and sizes.
(Courtesy of Ashcroft)

One of the most important accessories for any temperature-sensing element is a pressure-tight sheath known as a thermowell. This may be thought of as a thermally conductive protrusion into a process vessel or pipe allowing a temperature-sensitive instrument to detect process temperature without opening a hole in the vessel or pipe.

Thermowells are critically important for installations where the temperature element (RTD, thermocouple, etc.) must be replaceable without de-pressurizing the process.

Thermowells may be made out of any material that is thermally conductive, pressure-tight, and not chemically reactive with the process. Most thermowells are formed out of either metal (stainless steel or other alloy) or ceramic materials.

A simple diagram showing a thermowell in use with a temperature sensor (RTD) is shown here:

Typical RTD thermowell installation.

As useful as thermowells are, they are not without their caveats. All thermowells, no matter how well they may be installed, increase the first-order time lag of the temperature sensor by virtue of their mass and specific heat value. It should be intuitively obvious that a few pounds of metal will not heat up and cool down as fast as a few ounces’ worth of RTD or thermocouple, and therefore the addition of a thermowell to the sensing element will decrease the responsiveness of any temperature- sensing element. What is not so obvious is that such time lags, if severe enough, may compromise the stability of feedback control. A control system receiving a “delayed” temperature measurement will not see the live temperature of the process in real time due to this lag.

For more information on thermowells, contact Mead O'Brien by visiting https://meadobrien.com or by calling (800) 892-2769.

Five Important Criteria in Applying Pressure Gauges

Process pressure gauge.
(Ashcroft)

Pressure gauges are installed in countless industrial and commercial applications around the world. From hygienic pharmaceutical process lines, to the most unpleasant and hostile areas in chemical, power, and food processing plants.

While there are millions of possible combinations of shapes, sizes, options and materials, pressure gauges all share the five  following application criteria, required for safe use and long product life.

Diaphragm seal.
(Ashcroft)

1 - Process Media Properties: Media that is corrosive, sludgy, or that can solidify is a potential problem for pressure gauges. In non-corrosive, non-clogging media applications, a direct connection without intermediate protection can be applied. For process media that could potentially clog or chemically affect the gauge's wetted parts, a diaphragm seal should be used.

2 - Process Media Temperature: Very hot media, such as steam or hot water, can elevate the gauge's internal temperature leading to failure or an unsafe condition. For high temperature applications, the use of a "pigtail siphon" or diaphragm seal is recommended. Siphons act as a heat sink and lower the exposure temperature. Diaphragm seals isolate the gauge from the higher temperatures.

Pigtail siphon.

3 - Ambient Operating Temperature and Environment: It is important to know the ambient environmental rating for any process instrument. Elevated ambient temperatures, moisture, vibration, and corrosive atmospheres can all affect accuracy, calibration, and safety. Choose the proper housing and mechanism materials if oxidizing or reducing atmospheres exist, and consider the addition of ancillary devices, such as remote diaphragm seals to physically relocate the gauge away from the hostile area.

Snubber

4 - Severe Pressure Fluctuations: In applications where dramatic line pulsations or strong over-pressure conditions are a possibility, the use of pressure restrictors, snubbers, or liquid-filled gauges will extend the service life of the pressure gauge.

5 - Mounting: Pressure gauges are standardly available with bottom (radial) and back connections. NPT (National Pipe Thread Taper) threaded connections are generally the standard. Many other process connections are available though, such as straight threads, metric threads, and specialized fittings. Make sure you know how the gauge is being connected. When mounting, pressure gauges should be almost always be mounted upright.

For more information about pressure gauges, contact Mead O'Brien by visiting https://meadobrien.com or by calling (800) 892-2769.

Industrial Boiler and Burner Limit Control Switches

Ashcroft Limit Control Switch

Designers and manufacturers of industrial boilers are focused on meeting regulatory and safety requirements when developing highly efficient burner management systems (BMS). BMS are responsible for startup, operation and shutdown of a burner boiler systems. BMS monitor temperature, pressure and flow and employs safety shutoffs to shut down the burner boiler if an unsafe condition occurs.

The following white paper describes safety standards for boilers and burners relating to pressure switches and controls.

Read the embedded document below, or you can download your own PDF copy of "Industrial Boiler and Burner Limit Control Switches"  from the Mead O'Brien website here.

Industrial Boiler and Burner Limit Control Switches from Mead O'Brien, Inc.

Ashcroft Materials Compatibility and Corrosion Guide

Ashcroft products.

Below is a very good materials compatibility and corrosion guide courtesy of Ashcroft.

The reference is intended to serve solely as a general guide in the recommendation of materials for corrosive services and must be regarded as indicative only and not as any guarantee for a specific service.  There are many conditions which cannot be covered by a simple tabulation such as this, which is based on uncontaminated chemicals, not mixtures.

Many of the chemicals listed are dangerous or toxic.  No material recommendation should be made when there is insufficient information, a high degree of risk, or an extremely dangerous chemical.  The end user is responsible for testing materials in his own application, or for securing the services of a qualified engineer to recommend materials.

The end user is responsible for the choice of product(s) in his own application, based upon his own determination of the materials, chemical, and corrosion factors involved. THIS GUIDE AND ITS CONTENT ARE PROVIDED ON AN “AS IS" BASIS WITHOUT WARRANTY OF ANY KIND.

You can refer to the embedded document below, or you can download your Ashcroft Corrosion Guide PDF from this link.

Ashcroft Corrosion Guide from Mead O'Brien, Inc.

What Are Isolation Rings?

Isolation Rings (Ashcroft)

Isolation Rings are used for protection of sensitive and expensive pressure instrumentation, such as pressure switches, transmitters, and transducers. They isolate the instrument from an aggressive or viscous process. The Isolation Ring is mounted inline with process piping and fits between the process line pipe flanges, similar to wafer butterfly valves.

The ring design includes ring has a  flexible inner cylinder that prevents process media from collecting in the instrument, and therefore assuring reliable and continuous pressure measurement. An integrated needle valve allows for fast and easy removal for instrument repair, replacement, or calibration without interrupting the process media flow. The needle valve can also be used for pulsation dampening.

Watch the video below for a more in-depth understanding of how Isolation Rings are installed and operate.

For more information, contact Mead O'Brien by calling (800) 892-2769 or visiting https://meadobrien.com.

How to Use the Ashcroft 1305 Deadweight Tester

The Ashcroft 1305 deadweight tester provide a precise means for generating pressure with high accuracy that can be used as a primary calibration standard. The unit's built-in shuttle valve provides the means to control the rate of pressure increase, while precision adjustment is accomplished with an integral micro vernier displacement valve. 

This video below provides an overview of how to use the the Ashcroft 1305.

For more information on Ashcroft products, contact Mead O'Brien at (800) 892-2769 or visit http://www.meadobrien.com.

Industrial Pressure Switches

Industrial Pressure Switch (Ashcroft)

A pressure switch is a device that detects the presence of fluid pressure. Pressure switches use a variety of sensing elements such as diaphragms, bellows, bourdon tubes, or pistons. The movement of these sensors, caused by pressure fluctuation, is transferred to a set of electrical contacts to open or close a circuit.

Normal status of a switch is the resting state with stimulation. A pressure switch will be in its “normal” status when it senses low or minimum pressure. For a pressure switch, “normal” status is any fluid pressure below the trip threshold of the switch.

One of the earliest and most common designs of pressure switch was the bourdon tube pressure sensor with mercury switch. When pressure is applied, the bourdon tube flex's enough to tilt the glass bulb of the mercury switch so that the mercury flows over the electrical contacts, thus completing the circuit. the glass bulb tilts far enough to cause the mercury to fall against a pair of electrodes, thus completing an electrical circuit. Many of these pressure switches were sold on steam boilers. While they became a de facto standard, they were sensitive to vibration and breakage of the mercury bulb.

Pressure Switch Symbols

Pressure switches using micro type electrical switches and force-balanced pressure sensors is another common design.  The force provided by the pressure-sensing element against a mechanical spring is balanced until one overcomes the other. The tension on the spring may be adjusted to set the tripping point, thus providing an adjustable setpoint.

One of the criteria of any pressure switch is the deadband or (reset pressure differential). This setting determines the amount of pressure change required to re-set the switch to its normal state after it has tripped.  The “differential” pressure of a pressure switch should not to be confused with differential pressure switch, which actually measures the difference in pressure between two separate pressure ports.

When selecting pressure switches you must consider the electrical requirements (volts, amps, AC or DC), the area classification (hazardous, non-hazardous, general purpose, water-tight), pressure sensing range, body materials that will be exposed to ambient contaminants, and wetted materials (parts that are exposed to the process media).

Dampening the Effects of Vibration on Industrial Pressure Gauges

Vibration must be considered
when applying pressure gauges.

Pressure gauges rely on precise and responsive mechanisms to display changes in system pressure as rotational needle movement. By their very nature, these mechanisms are responsive to pulsations within the pressurized system and vibrations that may be evident in the connected piping and structures. The effect of vibration and pulsation is seen as an indicating pointer oscillating rapidly, making a definitive or even useful reading impossible. One solution, applied traditionally, was to fill the gauge with a viscous liquid that would dampen the rapid oscillation of the indicating needle.

While a liquid filled gauge does solve the oscillation problem, it does have a drawback. The liquid in the gauge presents its own set of operational issues requiring consideration in any application.

Provision should be made to check and maintain the liquid level in the gauge
A liquid filled gauge is an additional source of potential leakage in a facility

Ashcroft, a globally recognized manufacturer of gauges for commercial, industrial, and laboratory use, offers a different solution that provides the deflection dampening of a liquid gauge without liquid fill. Available on many of their gauges, the "Plus" option enables stable gauge face display in a dry gauge.

The video below provides a side by side demonstration of a liquid filled and a Plus gauge, so you can see the performance of both types. Share your process gauge requirements and challenges with instrumentation experts, combining your process knowledge with their product application expertise to develop effective solutions.

Understanding Differential Pressure or Delta-P

Differential pressure or Delta-P

Commonly, filters and strainers are positioned to capture solids and particulate. The filter will obstruct the flow through the pipe lowering the pressure on the downstream side. These effects may vary depending on the filters construction. Filter media is the material that removes impurities. The smaller the pores the larger the friction. Higher friction means greater pressure drop. Contaminants for particulates that buildup in the filter will reduce media flow. As the filter becomes clogged the downstream pressure drops. This results in an increased differential pressure, also referred to as the Delta-P. Saturated filters may also begin to shed captured particles.

With the filter no longer functioning properly, the contaminants can escape into the process. This is why proper monitoring of pressure drop is crucial. So how can we measure the DP? Placing taps both before and after the filter, a differential pressure measuring instrument can be connected to detect the high side and close side pressures. the instrument will report the difference between the two sides. The saturation point will be indicated when the Delta-P value reaches a predetermined threshold. This value is derived from a calculation that factors in the flow rate, fluid viscosity, and filter characteristics.

When specifying a differential pressure instrument there are two important factors to consider. The first is the DP range, which is based upon the most difference in pressure that the restriction is likely to produce. The second is the instruments ability to contain the line or static pressure level.

For more information on pressure measurement, call Mead O-Brien at (800) 892-2769 or visit www.meadobrien.com.

Here is a great video, courtesy of Ashcroft, that provides an excellent visual understanding of differential pressure.

Types of Pressure Measurements Used in Process Control

Pressure gauge
(courtesy of Ashcroft)

Pressure, the measure of a force on a specified area, is a straightforward concept, however, depending on the application, there are many different ways of interpreting the force measurement.

As with any type of measurement, results need to be expressed in a defined and clear way to allow everyone to interpret and apply those results correctly. Accurate measurements and good measurement practices are essential in industrial automation and process environments, as they have a direct effect on the success of the desired outcome.

When measuring pressure, there are multiple units of measurement that are commonly used. Most of these units of measurement can be used with the international system of units, such as kilo, Mega, etc.

This white paper (courtesy of Turck) will identify the various units of pressure measurement, while discussing when and why certain pressure measurements are used in specific applications.

Explanation of the Types of Pressure Measurements Used in Process Control from Mead O'Brien, Inc.