Educational information on process control, industrial instrumentation, valves, valve automation and control valves. For additional information visit IvesEquipment.com or call 877-768-1600
Remote Monitoring and Maintenance Through Digitalization - Siemens SITRANS store IQ Smart Monitoring Apps
How Often Should You Calibrate Your Toxic/Flammable Gas Detector?
When we think of gas detector calibration and how often it must be performed, it is dependent on many variables. First and foremost is determining if a gas sensor is out of calibration.
The best way to establish this is through a “bump” or functional test using a certified standard gas mixture of known concentration. If the device is functioning properly and still measuring gas within tolerance, calibration is unnecessary. Bump testing should be performed as regular maintenance on any gas detector. With the frequency depending on the sensor technology, manufacturer recommendations, specific company standard operating procedures and environment.
The two most common sensor types are NDIR and Electrochemical.
NDIR sensors tend not to drift and are calibrated prior to shipment. They require a bump testing frequency of 6 months or less to ensure performance is consistent. Calibration is only necessary if bump testing indicates the sensor is out of specification. Electrochemical sensors tend to drift over time and require bump testing every 3 to 6 months. Calibration is recommended annually or if bump testing indicates an out of spec sensor.
Due to the technology of electrochemical sensors, they will deplete over time and more rapidly if exposed to the target gas. They can also be poisoned if exposed to certain gases. If this is a risk, then bump testing more frequently is prudent. Calibration frequency can also be dependent on gas detector relevance. If it is a portable device, then it is pragmatic to bench calibrate before utilizing it in the field. If an area is planned to have significant traffic or work, then calibration should be performed for this event.
The sensor technology industry is constantly evolving, and with that newer sensors are assuring longer periods between calibration, or potentially no need to calibrate at all.
Using newly developed materials and software, sensors may last thousands of cycles without any performance decay, even if exposed to extreme environments or chemicals. The future is markedly promising.
Remember, the most important reason to calibrate your Vanguard Gas Detector is to provide accurate gas concentration readings in order that it could prevent illness, injury or death to personnel in the area. Your Vanguard may be exposed to extreme environments such as high or low temperatures, high or low humidity, or even harsh chemicals that may require more frequent calibration. With proper maintenance, your Vanguard can provide the safety your team deserves.
For more information about fixed toxic and flammable gas detection systems contact Ives Equipment. Call them at (877) 768-1600 or visit their website at https://ivesequipment.com.
The Weather is Changing. Freeze Protect Your Facility Now!
Ensure frigid temperatures don’t slow you down.
Nelson Electric Heat Trace.
LEARN MORE HERE
The Alfa Laval Unique Mixproof CP-3 Valve
Offering all dairy, food and beverage processors optimum hygiene, reliable effectiveness and decreased ownership expenses. Not just a dairy valve, the Alfa Laval Unique CP-3 is a reduced vent mix-proof valve – designed to be configurable and to protect your product.
Food and beverage plants across the United States are now using this proven mix-proof technology to eliminate cross-contamination – while improving overall production safety, hygiene, and production.
Beverage:
The Unique mix-proof CP-3 can be configured to handle carbonated drinks or energy drinks based on sugar and syrup – perfect for syrup or recipe room manifolds. Cleaning plugs and seats during seat-lifting eliminates sugar or syrup build-up.
Cleaning time and eventually modifications in the recipe are quicker as only two seals are situated in the valve chamber – enabling quicker valve cleaning during seat lift with fewer seal spare parts needed, improving valve longevity.
Food:
The Unique mix-proof CP-3 also has a setup to handle the most viscous condiments such as ketchup and mayonnaise and can assist address complicated problems in food processing – such as keeping the texture and taste of soups or vegetable sauces.
While it can be hard for any viscous food application to clean mix-proof valves with narrow plug tolerances, the starches left behind pose the greatest cleaning challenge. The valve seat is built on the upper and lower seat plugs with throttling corners – which speeds up cleaning fluid to enhance CIP effectiveness and clean the most stubborn food residue with the absolute minimum quantity of CIP fluid resources being used.
For more information, contact:
Ives Equipment
https://ivesequipment.com
(877) 768-1600
Examining the User Interface of the SensAlert ASI Gas Detector
The product is third-party certified to IEC61508 Level 2 (SIL-2) for both hardware and software with certification to global hazardous area and performance standards. The Test-on-Demand feature with on-board gas generator provides remote functionality checks with generated gas while Predictive Sensor End-of-Life Indication provides advanced warning of impending sensor failure.
SensAlert ASI is a universal instrument platform for toxic & combustible gas detection and oxygen monitoring. Intrinsically safe or explosion proof installation configurations with options for remote sensors and gassing, duct mount, and sample-draw maximize application versatility. Intrinsically safe or explosion proof installation configurations for remote sensors and gassing, duct mount, and sample-draw maximize application versatility. The sensor head accepts all Plus Series sensor technologies – infrared, catalytic bead, and electro-chemical. Assignable and configurable relays together with communication options provide broad flexibility. The SensAlert ASI I.S. sensor head can be remote mounted up to 100 feet (30m) from the transmitter providing a useful option to position the transmitter in a personnel-accessible location while positioning the sensor closer to potential hazards.
Food Processing: Belt Scales Improve Tomato Processor Efficiency and Productivity
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Belt Scales Improve Tomato Processing |
Application:
A tomato processor located on the Paciļ¬c coast uses the latest technologies in peeling, dicing, and packaging tomatoes. They were preparing to replace some of their older weigh feeders because of declining performance. One of their main concerns with installing new weigh feeders was the cost of moving the existing conveying systems in order to accommodate new weigh feeders.
See the document below for the full case history:
2 Wire, 3 Wire, and 4 Wire RTD Sensor Connections
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Industrial temperature transmitters (courtesy of Siemens) |
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Proper wiring of RTDs |
For more information about any temperature measuring application, contact:
Ives Equipment
www.ivesequipment.com
(877) 768-1600
Combustion Analyzer Adds Higher Level of Safety by Measuring O2, Combustibles, and Methane

Low emission burners and aggressive firing control points to achieve increased efficiency and emission reductions have driven the industry to tighter control measures. But tighter control measures also hold a greater potential for combustion events. Reducing the risk of a combustion event has become a priority and has led to the implementation of Safety Instrumented Systems (SIS). This additional layer of safety is added to the Basic Process Control System.
The WDG-V has been designed to provide an additional layer of safety with the measurement of excess O2, Combustibles and Methane and by using these measurements to ensure the safe operation of the Burner Management System.
Lost Plant Air a Hidden Source for Energy Savings
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Save energy costs by reducing consumption of plant air. |
Plant maintenance are becoming more aware of air leaks and the subsequent increases in cost to overcome lost power because of those leaks. One of the major culprits for lost air in a plant is the pneumatic control valve positioner and the air required to operate them. In a typical process plant, there could be hundreds of control valves. Each control valve uses a positioner to move the valve actuator, based on a set point signal from a controller.
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Control valve with Siemens SIPART |
Years ago, when electricity was cheap and when valve positioners were first introduced, plant maintenance and engineering were not concerned with something called the “bleed rate” of the positioner. Over the years though, plant personnel lost track of bleed rate and pretty much forgot that a positioner is just part of the system and it operates on air. Today, a modern process facility such as a power plant, refinery, or chemical plant can have several hundred control valves with positioners. The combined air loss due to the positioner “bleed rate” can be significant.
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Siemens SIPART positioners |
The significant change in technology came with the adoption of the adoption of a piezo ceramic valve block in low bleed positioners. Traditional positioners used an I/P and spool valve which both leaked air. Over time the leaks from these two parts is significant.
Could you and your plant be in the situation where lost energy efficiency through leaky positioners is costing big bucks? If you’re even the slightest bit concerned, call in an applications expert now for a system review.
Adhesives Manufacturer Saves Energy and Stays in Compliance with Flammability Anayzer
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Flammability analyzer increases safety while lowering energy cost. |
The 25% LFL applies to areas using just ventilation, but increases to 50% LFL if a continuous flammability analyzer is installed. If the manufacturer installed vapor analyzers, they could reduce the amount of energy on ventilation and fuel.
To meet the objective of lowering energy costs, the company installed PrevEx Flammability Analyzers, manufactured by Control Instrument Corporation, on each adhesive dryer. The PrevEx is a flammability analyzer for lower flammable limit monitoring (LFL/LEL) designed to provide fast response time (less than 1 second), capable of quickly changing gas concentrations, and with failsafe performance.
PrevEx flammability analyzers use a heated flame cell and an integrated controller that continuously measures total flammable vapor concentrations from 0 to 100% of the Lower Flammable Limit (LFL) range. To avoid condensation during sampling, the entire analyzer pneumatic assembly is heated.
A PrevEx analyzer was fitted on each printing press dryer to detect the possibility of solvent vapor accumulation. The PrevEx analyzers were chosen because of their "Universal Calibration" feature which prevents downtime due to re-calibration requirements.
By installing the flammability analyzers, the manufacturer was able to decrease ventilation and the associated energy costs while still staying in compliance with the NFPA code.
To understand more about flammability analyzers, look over the product document below:
For more information on flammability analyzers, contact:
Ives Equipment
www.ivesequipment.com
877-768-1600
Clamp-on Flowmeter Locates Hard-to-Find Water Plant Leak
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SITRANS FUP1010 clamp-on flowmeter |
The Problem
Unfortunately, the treatment plant was also losing 210,000 gallons a day due to an unknown leak.
Because of the leak, water storage was critically low at 100,000 gallons and the water service had to be temporarily shut off to half the village.
The village management hired a consultant company, at $1000.00 a day, to find the leak. The consultant worked for about a week without any luck.
PART 1: Setting Up and Operating the United Electric One Series Safety Transmitter
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One Series Safety Transmitter |
The One Series Safety Transmitter is a pressure or temperature monitoring transmitter switch that provides a NAMUR NE 43 standard 4-20 mA analog output. Its programmable high-capacity solid-state safety relay output enables the fastest emergency shutdowns.
The One Series Safety Transmitter is certified for use in SIL 2 functional safety applications (HFT = 0), and is capable of SIL 3 applications when augmented by redundancy and voting logic. Its simple design means fewer nuisance trips — for greater safety, productivity, and throughput.
The One Series Safety Transmitter was designed with features that simplify installation, improve productivity, and eliminate nuisance trips. “I Am Working” sensor diagnostics with redundant data processing detect open, shorted, and plugged sensing elements.
The transmitter’s analog output conforms to the NAMUR NE 43 standard and provides process variable (PV) and detected-fault information. Discrete outputs provide a fail-safe (open) emergency shutdown when a fault is detected. Set point and deadband (reset point) are 100% programmable.
The instrument is password protected to prevent unwanted parameter changes; eliminating the risk of tampering. In addition, LED backlighting enhances viewing of process variables, parameters, and status in dimly lit areas.
- Fewer nuisance trips for greater productivity
- More affordable than adapting a process transmitter for SIS
- Internal relay for faster emergency shutdowns
- Higher safe failure fraction simplifies SIL achievement
For more information, contact:
PART 2: Setting Up and Operating the United Electric One Series Safety Transmitter
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One Series Safety Transmitter |
The One Series Safety Transmitter is a pressure or temperature monitoring transmitter switch that provides a NAMUR NE 43 standard 4-20 mA analog output. Its programmable high-capacity solid-state safety relay output enables the fastest emergency shutdowns.
The One Series Safety Transmitter is certified for use in SIL 2 functional safety applications (HFT = 0), and is capable of SIL 3 applications when augmented by redundancy and voting logic. Its simple design means fewer nuisance trips — for greater safety, productivity, and throughput.
The One Series Safety Transmitter was designed with features that simplify installation, improve productivity, and eliminate nuisance trips. “I Am Working” sensor diagnostics with redundant data processing detect open, shorted, and plugged sensing elements.
The transmitter’s analog output conforms to the NAMUR NE 43 standard and provides process variable (PV) and detected-fault information. Discrete outputs provide a fail-safe (open) emergency shutdown when a fault is detected. Set point and deadband (reset point) are 100% programmable.
The instrument is password protected to prevent unwanted parameter changes; eliminating the risk of tampering. In addition, LED backlighting enhances viewing of process variables, parameters, and status in dimly lit areas.
The Series One leads the market in process safety transmitters because:
- Fewer nuisance trips for greater productivity
- More affordable than adapting a process transmitter for SIS
- Internal relay for faster emergency shutdowns
- Higher safe failure fraction simplifies SIL achievement
Compact NTEP Approved Custody Transfer Coriolis Flowmeter Means Easier Installation and Space Savings
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SIEMENS SITRANS FC430 |
By combining the Siemens SITRANS FCS400 sensor and SITRANS FCT030 transmitter, the digitally based SITRANS FC430 is suitable for applications within the process industries. It is also one of the first Coriolis systems worldwide to achieve SIL 2 and 3 approval in hardware and software, respectively – the ultimate assurance of safety and reliability.
The SITRANS FCT030 transmitter delivers multi-parameter measurements with enhanced efficiency, simplicity and security. Available in a modular design, it can be remote or compact-mounted with all SITRANS FCS400 sensor sizes. An enclosed micro SD card serves as a removable database of operational information and provides direct access to all certificates and audit trails.
The SITRANS FC430 is ideal for a broad array of process industries and applications, including:
- Chemical. Designed for optimal performance in hazardous areas and compliant with a wide variety of certificates and approvals, including SIL 2 (hardware), SIL 3 (software), FM, ATEX, CSA
- Food & Beverage/Pharmaceutical. High level of accuracy improves quality control, while multi-parameter measurement ability strengthens process management.
- Oil & Gas. NTEP approved for custody transfer and capable of measuring mass flow directly, ensuring performance is not affected by fluctuating process conditions. Unique tube design results in minimal pressure loss and high resistance to process noise.
- Affiliated Industries/OEMs. Highly customizable nature offers versatility to meet the needs of customers in many different businesses, from food and beverage to automotive to HVAC, to oil and gas to pulp & paper and beyond.
Compact Coriolis Flowmeter with NTEP Custody Transfer Approval
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NTEP approval for custody transfer |
When oil and gas are physically transferred from one operator to another, the term custody transfer is used to describe the transaction. It is understood as the transfer of fluid material defined by a metering device, at a given location, to another party. Custody transfer occurs at a variety of locations including from production platforms to ships, trucks, railcars, barges, and also at the final destination, such as the processing plant or refinery.
Accuracy is very important in custody transfer as both parties and instruments such as flowmeters must have approval by the organizations such as the American Petroleum Institute (API) or the National Conference on Weights and Measures (NCWM).
The National Type Evaluation Program (NTEP) is an evaluation program overseen by the National Conference on Weights and Measures (NCWM). Manufacturers who carry NTEP approval comply with local state and government regulations regarding transactions selling, purchasing, exchanging, custody transfer, or establishing the cost for services on based on weight.
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Compact Coriolis flowmeter with NTEP approval |
For more information, contact:
Ives Equipment
www.ivesequipment.com
877-768-1600
Major Water Savings in Dairy Operations White Paper
Alfa Laval describes a better way to clean double-seat mixproof valves and reduce water and CIP liquid consumption even further. This involves quick and repetitive opening and closing of the seat, rather than exposing valve surfaces to CIP liquid ow for a given duration of time. This discovery was made at one of Alfa Laval’s process facilities. Alfa Laval engineers observed that, during the first fractions of a second of a cleaning cycle, the ow of CIP liquid created a high level of shear stress on the valve surfaces used less water than traditional seat lift and seat push cleaning, and increased overall cleaning efficiency.
Selecting Valves Used in Wine Production and Craft Brewing
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Valves and Sensors used in wine and beer making. |
Installing the Siemens SITRANS FUS1010 Clamp-on Industrial Flowmeter
The SITRANS FUS1010 is one of the most versatile clamp-on ultrasonic flowmeters available. Because it can operate in either WideBeam transit time or Doppler mode, there is no need to change the meter when operating conditions change. This makes it suitable for virtually any liquid, even those with high aeration or suspended solids.