Physical Property Analyzers

PCI 108.04

Saudi Aramco

Physical Property Analyzers for Refinery Applications

Saudi Aramco Professional EngineeringDevelopment Program

PCI 108.04 2

Terminal Objective

Upon completion of this module, the Participant will be able to evaluate physical property analyzers for specific refinery applications, in terms of suitability for installation, operational capabilities, and maintenance requirements, using appropriate guidelines and vendor data.

PCI 108.04 3

Enabling Objectives

1. Evaluate boiling point/distillation analyzers, using applicable guidelines and vendor data.

PCI 108.04 4

Enabling Objectives

2. Evaluate vapor pressure analyzers, using applicable guidelines and vendor data.

PCI 108.04 5

Enabling Objectives

3. Evaluate octane analyzers, using applicable guidelines and vendor data.

2. Evaluate vapor pressure analyzers, using applicable guidelines and vendor data.

PCI 108.04 6

Enabling Objectives

4. Evaluate flash point analyzers, using applicable guidelines and vendor data

PCI 108.04 7

Enabling Objectives

5. Evaluate viscosity analyzers, using applicable guidelines and vendor data.

PCI 108.04 8

Enabling Objectives

5. Evaluate viscosity analyzers, using applicable guidelines and vendor data.

6. Evaluate color analyzers, using applicable guidelines and vendor data.

PCI 108.04 9

INTRODUCTION

� Process Analyzer Calibration and Validation

� Scope of Module

• Absolute or real calibration• Relative or arbitrary calibration

BOILING POINT & DISTILLATION ANALYSERS

PCI 108.04 11

Evaluating Boiling Point/Distillation Analyzers

• Function - To measure the temperature of a specific boiling point of a process stream for the purpose of product specification monitoring and/or advanced process control.

PCI 108.04 12

• Function• General Applications

– Crude Distillation Control

PCI 108.04 13

Crude Distillation Control

Figure 1Figure 1

O/H Accumulator

O/H Cooler

Overhead Distillate

No. 1 S/S Stripper Steam

No. 1 Sidestream

Pumpback reflux

No. 2 S/S Stripper

Steam No. 2 Sidestream

No. 3 S/S Stripper

Steam No.3 Sidestream

Steam Crude Feed

Preheat Furnace

Mid pump-around

Top pump-around

Flash Zone

Bottoms

PCI 108.04 14

Ras Tanura Refinery - Plant 52 Diesel Blender - ABB Sim Dis Ras Tanura Refinery - Plant 488 & 493 Rheniformer - ABB Sim Dis

— Crude Distillation Control— Fuels Blending Control

PCI 108.04 15

• Function• General Applications• Process Analytical Techniques for

Boiling Point/Distillation Measurement– Principles of Operation

PCI 108.04 16

ASTM D86 Test Apparatus

Figure 2

Xi Z i Yi 1.00

Liquid

Mole Fraction ofComponent

ConstantPressure (P)

Figure 2

Distillation Thermometer

100 mL Sample

Heater

Condenser

Cardboard Cover

Graduated Cylinder

Engler flask

Ice Water Bath

PCI 108.04 17

Typical ASTM D86 Distillation Curve

Figure 3

400(204)

350(177)

300(149)

250(121)

450(232)

Volume Recovered (mL)10 20 30 40 50 60 70 80 90

C4 Polymer

TS-28 Solvent

ASTM-D86

PCI 108.04 18

Boiling Point/Distillation Measurement– Principles of Operation– Configuration of Boiling Point/Distillation

Analyzers

PCI 108.04 19

Process Boiling Point Analyzer Manufacturers

Figure 4

Manufacturer Model No. Type

Carlo Erba (Italy) PD-155 5-95% Point

Ludlum Sysco Ltd. 1463 5-97% Point(UK) 1463M 5-97% Point

Distillar 2000 IBP to FBP

Precision Scientific 44520-11 5-95% PointInc. (USA) 44522 5-95% Point

BPA-II 5-95% Point41468 Vac. Dist.

PCI 108.04 20

Configuration of Boiling Point/Distillation Analyzers

• Continuous Boiling Point/Distillation Analyzers

PCI 108.04 21

Precision Scientific BPA-II Boiling Point Analyzer

Figure 5

SamplePressure

#1Amp.

#2Amp.

ManualFlushingValve

SampleOutletValve

Air Supply

Safety Out

SampleIn

Strainer

Eductor(Optional)

SampleOut

FilterCoalescer

Over-headsOrifice

Bot-toms

Orifice

4-20mA(isolated)

InletValveT/C

Reboiler

Note: Valve configuration shown asprior to start-up or upon fail safe.

BPA II

PCI 108.04 23

Precision Scientific Vacuum Distillation Monitor

Figure 6

N.O.N.C.Steam traced andinsulated line

PressureController

PressureTransmitter

Coolant

Sample In

DistillationTower

ThermocoupleOut

115/230VAC

Reboiler

RuptureDisc

ToAtmosphereVacuum

SurgeVessel

VacuumPump

VacuumDrainVessel

SampleOut

Condenser

Overheads

Reflux

SightGlass

Overheads Pump

BottomsPump

Oil-filled Bath Housing

VACUUM DISTILLATION MONITOR 441468

PCI 108.04 25

Precision Scientific Model 44522 Boiling Point Analyzer

Figure 7

L.E.D.Display

DigitalKeyboard

AlphanumericDisplay

MicroprocessorUnit

(M.P.U.)

Differential PressureRegulator

PressureRegulator

FilterSampleIn

CoolantIn

Remote Set Point

Alarms

Measured Variable

Coolant Temperature

Coolant Out

Sample Out

Pump RPM

Pump Suction Head

Heater Volts and Thermocouple Output

Sample TemperatureAtmospheric Pressure

D/P Sensor

Standpipe

BottomsPump

Filter

ExhaustPump

EvaporatorColumn

% distilled 38 to 343C or 5% to 95% recovered

PCI 108.04 27

Sysco (Rotork Analysis) Model 1463 Boiling Point Analyzer

Figure 8

ThermocoupleSignal Out

LevelController

Power In SampleVent

FlameTrap

Dra in

Overflow

Tube in TubeHeat Exchanger

0 to 14 Bar g

0 to 93C

SampleFlowmeter

SampleIn

Sample PumpNo. 1 In

Measure Sample PumpNo. 2 Cut

Measure

10 Bar g 14 Bar g

HeatExchanger

17 Bar g

Flash Cup

LevelSensor

5% to 97% recovered or % distilled 65 to 350C

PCI 108.04 28

• Continuous Boiling Point/Distillation Analyzers • Analyzers that Duplicate the ASTM D86 Test

Method

PCI 108.04 29

Rotork Analysis (Hone) Distillar 2000 Boiling Point Analyzer

Figure 9

Flame Trap

Receiver DrainReceiver Overflow

Flask Drain

Receiver Valve

FlaskValve

BuretteValve

SampleValve

Burette

Burette VentVent toSafe Height

AnalyzerBox

EndPoint

DetectorDetector

CoolingWater In

Heater

WaterOut

Recov-eryVolume

ReceiverVent

SampleOverflow

SampleIn

Sample

• Initial Boiling Point• Recovery Point• Distillation Point• End Point• Total Recovery• Continuous Recovery• Continuous Temp

PCI 108.04 30

Rotork Analysis (Hone) Distillar 2000 Boiling Point Analyzer

• Initial Boiling Point• Recovery Point• Distillation Point• End Point• Total Recovery• Continuous Recovery• Continuous Temp

PCI 108.04 31

• Continuous Boiling Point/Distillation Analyzers • Analyzers that Duplicate the ASTM D86 Test Method • Simulated Distillation Analyzers

– ASTM D2887 & D3710

PCI 108.04 32

Process GC Sim-Dis -Aramco Applications

Ras Tanura Refinery - Plant 52 - Diesel BlendingRas Tanura Refinery - Plant 488 - RheniformerRas Tanura Refinery - Plant 492 - Rheniformer

PCI 108.04 34

Process GC Sim-Dis Analyzer Manufacturers

Figure 10

PROCESS GC SIM-DIS. ANALYZERS

Manufacturer Model No.

ABB Process Analytics VISTA GC(USA) VISTA SFC

Strms.

Applied Automation ADVANCE GC(USA)

Fluid Data/Amscor MS-IV-BP(USA)

Foxboro Analytical Model 931C(USA)

Rosemount Analytical Model 6750(USA)

UOP Monirex Systems B Pt. Monitor(USA)

PCI 108.04 35

• Function• General Applications• Process Analytical Techniques for Boiling

Point/Distillation Measurement• Installation Considerations

PCI 108.04 36

Boiling Point/Distillation Measurement• Installation Considerations• Operational Considerations

PCI 108.04 37

Boiling Point/Distillation Measurement• Installation Considerations• Operational Considerations• Maintenance Considerations

PCI 108.04 38

Boiling Point/Distillation Measurement• Installation Considerations• Operational Considerations• Maintenance Considerations• Specific Application Evaluation

PCI 108.04 39

Typical Atmospheric Pipestill

Figure 11

O/H Accumulator

O/H Cooler

Overhead Distillate

No. 1 S/S Stripper Steam

No. 1 Sidestream

Pumpback reflux

No. 2 S/S Stripper

Steam No. 2 Sidestream

No. 3 S/S Stripper

Steam No.3 Sidestream

Steam Crude Feed

Preheat Furnace

Mid pump-around

Top pump-around

Flash Zone

Bottoms

PCI 108.04 40

Flow Diagram - Crude Atmospheric Distillation

Figure 12

No. 1 S/S Stripper

SteamKerosene

No. 2 S/S Stripper

SteamDiesel Fuel

No. 3 S/S Stripper

SteamLight Gas Oil

No. 4 S/S Stripper

SteamHeavy Gas Oil

TopPumparound

MiddlePumparound

BottomPumparound

CrudeFeed

AtmosphericPipestill

FlashZone

Residue to Vacuum Pipestill

O/H Condenser

To Fuel GasRefluxDrum

95% Point

PCI 108.04 41

Sample Handling System for a Boiling Point Analyzer

Figure 15

SampleReturn

FastLoop

Fast LoopFlowmeter

FastLoopFilter

LabSamplePoint

SampleCooler

Coolant

PressureRegulator

DualFilter-Coalescer

System

Water toDrain

SecondaryBypass

To SampleRecoverySystem

PCI 108.04 42

Perform Exercise 1

PCI 108.04 43

Exercise 1 Key

Figure 87

PressureRegulator

Waterto Drain

SampleReturn

SampleTap

FastLoop

Fast LoopFlowmeter

FastLoopFilter

LabSample

Coalescer

BoilingPoint

Analyzer

VAPOUR PRESSURE ANALYSERS

PCI 108.04 45

Evaluating Vapor Pressure Analyzers

• Function - to measure the vapor pressure of a liquid process stream in order to monitor a product specification or to provide data for advanced control of fractionators and blending systems.

PCI 108.04 46

• Function • General Applications

– Fuels Blending

PCI 108.04 47

Vapor Pressure Analysers

Laboratory Methods:ASTM D323 Volatile Crude Oil & Volatile Petroleum ProductsASTM D1267 Liquid Petroleum GasesASTM D5482 (93) Mini Method - Atmospheric

PCI 108.04 48

Evaluating Vapor Pressure Analyzers• Function • General Applications

Juaymah Gas Plant- RVP Tower - TOTCO

PS3 RVP Arab Super Light - ABB– Fuels Blending

Ras Tanura Refinery - Plant 28 MOGAS BLEND - ABB

PCI 108.04 49

• Function • General Applications

– Fuels Blending– Vapor-Liquid Ratio Measurement

Ras Tanura Refinery - Plant 28 MOGAS Blend - Core Labs

PCI 108.04 50

• Function • General Applications• Process Analytical Techniques for Vapor Pressure

Measurement– Principles of Operation (Reid Method ASTM

PCI 108.04 51

Measurement– Principles of Operation (Reid Method ASTM

D323)– Configuration of Vapor Pressure Analyzers

PCI 108.04 52

Configuration of Vapor Pressure Analyzers

• Reid Vapor Pressure Analyzers

PCI 108.04 53

Precision Scientific Reid Monitor Model 44770

Figure 16

Reid Monitor

20 PSIG Air Supply

3-15 PSIG Output

Coolant

Sample In

SampleOut

PressureTransmitter

Coolant

CalibrationValve

FeedPump

PumpMotor Exhaust

CircPump

SaturationChamber

OilBath

0.3-148PSIG

Feedback

SealPot

PCI 108.04 54

ABB Process Analytics RVP Analyzer Model 4100

Figure 17A

PCI 108.04 55

ABB Process Analytics RVP Analyzer Model 4100

Figure 17B

Transducer Output Once Cycle 1 Purge cell 2 False fill 3,4,5 3 each 20 sec. purges of cell 6 Zero pressure reading 7 20 sec. sample filling cell 8 4 min. equilibration and final pressure reading Diagnostics During One Cycle A. Temperature and temperature runaway monitoring and over pressure protection B Air purge pressure test C Zero reading pressure transducer test D Level sensor test E Sample fill test F Cell leak test and RVP temperature confirmation

R 5 4 3

PCI 108.04 56

• Reid Vapor Pressure Analyzers• Kinetic (or Absolute) Vapor Pressure Analyzers

PCI 108.04 57

Precision Scientific Absolute Vapor Pressure Analyzer - Principle

Figure 18

V 1 V 2 Incoming Sample

Sensing Device

Measuring Chamber

PCI 108.04 58

Principle Precision Scientific Absolute Vapor Pressure Analyzer - Layout

Figure 19

Inlet Pressure Regulator

TemperatureController

BathHeater

Hi-temp C/O

EjectorAssembly

Back PressureRegulator

ASTMThermometer

SampleOil

StirringMotor

SampleIn

Coolant

Filter

PCI 108.04 59

• Reid Vapor Pressure Analyzers• Kinetic (or Absolute) Vapor Pressure Analyzers

TOTCO CVPT

PCI 108.04 60

• Reid Vapor Pressure Analyzers• Kinetic (or Absolute) Vapor Pressure Analyzers• Vapor/Liquid Ratio Analyzers

Ras Tanura Refinery - Plant 28 MOGAS Blender

PCI 108.04 61

Core Labs Volrac V/L Ratio Analyzer

Figure 20

LiquidVolumeSignal

VaporLiquid

Separator

VaporFlowMeter

TempControlHot Oil

Hot Water

ElectricWaterHeaterMechanical

Chiiller CalculateAnalyzed V/L

CalculateDelta V/L

(Anal-Targ)

V/L A V/L

Signal for Remote Devices

V/L = 8/40 V/L = 40StandardFuel

Control Instruments& Analog Computation

V-L SeperatorTemperature

Controller

V/LTemperature

SelectSwitch

VaporVolumeSignal

Target V/LSelectSwitch

FilterCoalescer

Cooler

Fuel Sample Loop

Excess FuelFuelMetering

Excess Fuel

PCI 108.04 62

Measurement• Installation Considerations

PCI 108.04 63

Measurement• Installation Considerations• Operational Considerations

PCI 108.04 64

Measurement• Installation Considerations• Operational Considerations• Maintenance Considerations

PCI 108.04 65

Measurement• Installation Considerations• Operational Considerations• Maintenance Considerations• Specific Application Evaluation

PCI 108.04 66

Flow Diagram - Gasoline Blending Process

Figure 21

SP SP SP SP SP

GasolineBlending

Feed Stocks

Master Oscillator

Vapor Pressure

PumpedFast Loop

Blend HeaderGasolineProduct

TurbineMeter

PCI 108.04 67

Sample Handling System for a Vapor Pressure Analyzer

Figure 24

SampleReturn

SampleTap

FastLoop

Fast LoopFlowmeter

FastLoopFilter

LabSample

Coalescer

PressureRegulator

Water toDrain

PressureRegulator

To SampleRecovery

VaporPressureAnalyzer

Water toDrain

PCI 108.04 68

Perform Exercise 2

PCI 108.04 69

Exercise 2 Key

Figure 88

PressureRegulator

SampleReturn

SampleTap

FastLoop

Fast LoopFlowmeter

FastLoopFilter

Lab SamplePoint

PressureRegulator

VaporPressureAnalyzer

StandardSample

OCTANE ANALYSERS

PCI 108.04 71

Evaluating Octane Analyzers

• Function - to measure the octane number of intermediate feedstocks for gasoline blending and octane number of the final blended gasoline.

PCI 108.04 72

– Gasoline Blending

PCI 108.04 73

– Gasoline Blending– Refinery Processes

PCI 108.04 74

– Gasoline Blending– Refinery Processes– Feedstocks for Gasoline Blending

PCI 108.04 75

• Function• General Applications • Process Analytical Techniques for Octane

Number Measurement– Principles of Operation

PCI 108.04 76

ASTM-CFR Engine for Octane Testing

Figure 25

A. Inake Surge Pipe B. Coolant Condenser C. Exhaust Surge Tank D. Exhaust Manifold E. Crank for Adjusting Compression Ratio F. Oil Drain Cap G.Waste Fuel Can, Closed for Safety H I. J. K. L. M. N.

Ignition Breaker Cylinder Clamp Intake Air Thermometer Ignition Coil Detonation Meter , Model 501-T Knockmeter

O. Temperature Controller

Oil Filter

PCI 108.04 77

ASTM-CFR Engine for Octane Testing

•Compression Ratio 4-18•Coil & Distributor Ignition•Spark advance indicated•RON advance set at 13BTDC•RON SPEAD 600rpm

PCI 108.04 78

ASTM-CFR Engine for Octane Testing - Bracketing - Procedure A - ASTM D2699

ENGINE STANDARDIZTION

RUN SAMPLE FUEL

RUN REFERENCE FUEL 1

RUN REFERENCE FUEL 2

ON PRF :•SET CYL HEIGHT•FUEL LEV FOR MAX KI•SET METER TO 50 +/-2

•ADJUST CYL HEIGHT SO KI =MIDSCALE•FUEL LEV FOR MAX KI•ADJUST CYL HEIGHT 50+/- 2•RECORD CYL HEIGHT AND •FROM GUIDE TABLES EST ON

•RUN REFERENCE FUEL 1:•FUEL LEVEL FOR MAX KI

•RUN REFERENCE FUEL 2:•FUEL LEVEL FOR MAX KI

PCI 108.04 79

ASTM-CFR Engine for Octane Testing - Bracketing - Procedure A - ASTM D2699

PCI 108.04 80

Number Measurement– Principles of Operation – Configuration of Octane Analyzers

PCI 108.04 81

Configuration of Octane Analyzers

• Analyzers Based on the ASTM-CFR Engine – Knock Intensity Method

PCI 108.04 82

Core Labs Model 8154 Octane Comparator System

Figure 27

O.N. Recorder X FlowIntegrator

CrankcaseVentExhaust

OctaneAnalyzerConsole

OctaneAnalyzer

Fuel Cooler

OctaneAnalyzer

FuelConditioner

ASTMEngine

byWaukesha

OctaneAnalyzerInterface

Prototype FuelStorage System

ExcessFuel

Return

SampleLoop

Power (Single Phase)Power (Three Phase)Cooling Water

BlenderControlModifier

PCI 108.04 83

Core Labs Model 8154 Octane Comparator System (KI Method)

Figure 28

Rotometer

CoolantExchanger

SolenoidValve

CoolantExchanger

SolenoidValve

ProtoPump

ProtoSafetyCan

SampleLoop

ProtoTanks

FilterCoalescer

Pressure Regulator

FuelSelectionValve

Octane Analyzer-Fuel System

BypassConn.

ASTMEngine

PCI 108.04 84Figure 28

Core Labs Model 8154 Octane Comparator System (KI Method)

SampleTimer

ProtoTimer

Fuel Selector Valve

Proto Track &Hold Module

Sample Track &Hold Module

Octane Analyzer-Programmer Functions

Programmer

PCI 108.04 85

• Analyzers Based on the ASTM-CFR Engine – Knock Intensity Method– Compression Ratio Method

Core Labs Model 8154 Octane Comparator System (CR Method)

C RControl

Carburetor

ASTMEngine

DetonationMeter

C RMotor

C R MotionTransmitter

Excess Fuel

Sequencing

ProductTrack& Hold

Offset

ProtoTrack& Hold

AddSubt

Delta O.N.Display

2 Gal.Aux Proto

Bulk Proto

Product SampleLoop

Filter &Coalescer

FuelCooler

Constant Knock Intensity-CompressionRatio Control System

Knockmeter

Pickup

DetonationMeter

CompressionRatio

Controller

C.R.Motor

ASTMEngine

Proto Track &Hold Module

t rack Hold Module

Span Offset

AdderModule

O.N.Output

O.N.Meter

Sequenc ing

C.R. Measurement and Delta ON SignalGeneration System

ASTMEngine

Sample T

PCI 108.04 89

Associated Octel Octane Comparator System

Figure 29

PCI 108.04 90

Associated Octel Octane Comparator System - Operating Sequence

Figure 30

LineGasoline

ReferenceGasoline

LineGasoline

ReferenceGasoline

210 sec. Time

PCI 108.04 91

• Analyzers Based on the ASTM-CFR Engine • Analyzers Based on Correlative Techniques

PCI 108.04 92

UOP Monirex Octane Analyzer

Figure 31

Increase inOctane ShiftsPeak

TE - 1 TE - 2

25.4 mmReactor Tube Length

TE1 TE2

PSL MM

PressureTransmitter

Temperature DifferentialController

(High)(Low)PressureSwitches

ReactorChamber

PressureController

PreheaterMetering

SampleInlet

SampleBypassLoop Bath

Heater

Afterburner

Vent to Stack

RowController

PressureController

Instrument Air

Increase inPressureShifts Peaks

A. Flow Schematic

B. Peak Temperature Curve

PCI 108.04 93

UOP Monirex Octane Analyzer

Figure 31

Increase inOctane ShiftsPeak

TE - 1 TE - 2

25.4 mmReactor Tube Length

TE1 TE2

PSL MM

PressureTransmitter

Temperature DifferentialController

(High)(Low)PressureSwitches

ReactorChamber

PressureController

PreheaterMetering

SampleInlet

SampleBypassLoop Bath

Heater

Afterburner

Vent to Stack

RowController

PressureController

Instrument Air

Increase inPressureShifts Peaks

A. Flow Schematic

B. Peak Temperature Curve

PCI 108.04 94

Foxboro Model 81P Octane Analyzer - Operating Conditions

Figure 32

Oxidation Reactions of Fuel-Air Mixes vs T emperatures

400350

300250200

Spontaneous Combustion

Cool Flames

Partial Oxidations

Little or Nor Reactions Occur

Thermocouple Output vs T ime for T ypical Gasoline

0 6 12 18 24 30Time, (sec)

SampleInjection

InductionPeriod

Heat ofVaporization

Temp. Max. orSeverity

RON vs Severity vs T emperature

.2 .6 1.0 1.4 .1.8

300 C 305 C310 C

PCI 108.04 95

Foxboro Model 81P Octane Analyzer - Operating Conditions

Figure 32

Oxidation Reactions of Fuel-Air Mixes vs T emperatures

400350

300250200

Spontaneous Combustion

Cool Flames

Partial Oxidations

Little or Nor Reactions Occur

Thermocouple Output vs T ime for T ypical Gasoline

0 6 12 18 24 30Time, (sec)

SampleInjection

InductionPeriod

Heat ofVaporization

Temp. Max. orSeverity

RON vs Severity vs T emperature

.2 .6 1.0 1.4 .1.8

300 C 305 C310 C

PCI 108.04 96

Foxboro Model 81P Octane Analyzer - Layout

Figure 33

Customer ServiceConnection(115 VAC)

DisplayHousing

PowerSwitch

FieldConnection

Oven TemperatureController

Flow PanelOutline

Pump AirFilter/Reg./Oiler

Drip PotAssembly

ReactorHousing(Oven)

MicroProcessorHousing

Air Heater/Sensor/Fan

Measuring T.C.

Reactor Block

Insulation

Air and SampleInlets

ChromatographicType Inject ValveSample Outlet

Reference T.C.

Reaction ZoneCavity

Reactor Heaters

Drip PotTo Vent and Flash

Back Arrestor

Reactor Housing

PCI 108.04 97

• Analyzers Based on the ASTM-CFR Engine • Analyzers Based on Correlative Techniques• Analyzers Based on FTIR/FTNIR Spectrometry

PCI 108.04 98

Analyzers Based on FTIR/FTNIR Spectrometry

PCI 108.04 99

VISIBLE SPECTRUM

PCI 108.04 100

Near Infra Red

PCI 108.04 101

PCI 108.04 102

Ras Tanura Refinery - Plant 28 RON & MON

PCI 108.04 103

PCI 108.04 104

PCI 108.04 105

Interferogram

PCI 108.04 107

Interferogram

PCI 108.04 108

• Analyzers Based on the ASTM-CFR Engine • Analyzers Based on Correlative Techniques• Analyzers Based on FTIR/FTNIR Spectrometr

PCI 108.04 109

Number Measurement• Installation Considerations

PCI 108.04 110

Number Measurement• Installation Considerations• Operational Considerations

PCI 108.04 111

Number Measurement• Installation Considerations• Operational Considerations• Maintenance Considerations

PCI 108.04 112

Number Measurement• Installation Considerations• Operational Considerations• Maintenance Considerations • Specific Application Evaluation

PCI 108.04 113

Flow Diagram - Gasoline Blending Process

Figure 34

RatioFCFC

SP SP SP SP SP

Gasoline BlendingFeed Stocks

Master Oscillator

OctaneNumber

PumpedFast Loop

Blend HeaderGasolineProduct

TurbineMeter

PCI 108.04 114

Typical Sample Handling System for an Octane Analyzer

Figure 37

Fast LoopFlowmeter

FastLoopFilter

Coalescer

PressureRegulator

Fuel Selector Valve

Water toDrain

SampleCooler

Coolant

To ASTM-CFR Engine

ProtoCooler

CoolantPressureRegulator

ShutoffValvesF

PrototypeFuel Storage

ProtoPump

PCI 108.04 115

Perform Exercise 3

PCI 108.04 116

Exercise 3 Key

Figure 89

SampleReturn

SampleTap

FastLoop

Fast LoopFlowmeter

FastLoopFilter

LabSample

Point To SampleRecovery

OctaneAnalyzer

FLASH POINT ANALYSERS

PCI 108.04 118

Evaluating Flash Point Analyzers

• Function - to measure the flash point of intermediate and final product streams in order to monitor a final product flash point specification, or to provide data for advanced process control.

PCI 108.04 119

– Crude Distillation– Fuels Blending

PCI 108.04 120

• Function• General Applications• Process Analytical Techniques for Flash Point

Measurement– Principles of Operation

PCI 108.04 121

ASTM D56 Flash Point Test Apparatus

Figure 38

Bath Stand forGas Burner

Overflow

Cup Thermometer

FlameTip

OilChamber

Test Cup

Gas Burner

BathThermometer

FlameSizeBead

PCI 108.04 122

ASTM D93 Flash Point Test Apparatus

Figure 39

4.3741.941.58

. . .57.236.35

5.1642.063.189.52

57.86. . .

(0.172)(1.651)(0.062)(. . . )(2.253)

min max

mm inches

(min) (max)

(0.203)(1.656)(0.125)(0.375)(2.278)(. . .)

ABCDEF (0.25)

Distance PieceD

Note-Lid assembly may be positioned either right or left-handed.

Handle (Optional)(Must not tipempty cup)

Stirrer Drive FlexibleShaft (Pulley drive optional)Flame ExposureDevice Shutter Operating

F-Min. thicknessover cup area i.e.,metal surroundingthe cupHeater Flame-Type or ElectricalResistance Type(Flame Type Shown)

Shutter

Test CupStove Top Plate

Air Bath

Air Gap

PCI 108.04 123

Measurement– Principles of Operation– Configuration of Flash Point Analyzers

PCI 108.04 124

Configuration of Flash Point Analyzers

• Analyzers that duplicate ASTM Test Methods

PCI 108.04 125

Precision Scientific General Flash Point Monitor Model 44650

Figure 40

PressureSwitch

L.P. Steam

PumpAssembly

P-1 P-2

Measuring Chassis

SampleHeater

Press.Reg. Sample

F.A.S.

Control Chassis

SolenoidValve

(Heating)

(Cooling)

115V.A.C.H.V.Elect.

Flash Cup

Sample Out

DrainFilter

115V.A.C.

Separator

PCI 108.04 126

Precision Scientific Flashpointer Model 44607

Figure 41

Connections:

1/8 FPT1/4 FPT3/4 FPT1/8 FPT1/4 FPT

Sample Inlet -Sample Outlet -Electrical (2) -Combustion Air -Purge Air -

VaporVent LaneHigh V oltage

Electrode

VaporThermocouple

LiquidThermocouple

Air In

Sample In

118 VAC

SampleHeater

SampleOutlet

LiquidDrainLine

SplashShield

ControlAssembly

PurgePurge

SampleIn

CombustionAir

PowerIn

SampleOut

FlashChamber

Flash Pointer

(MeasurementAssembly)

PCI 108.04 127

Precision Scientific Integrated Flash Point Monitor Model 44624

Figure 42

2= Denotes Relief Valve & Setting (kg./cm )5.0

SampleOut

PSDCatalog44807

FlashPointer

Vent FlameArrester

MechanicalRefrigeration

BlockValve

CalibrationValve

DryFiltered

AirSupply

SolenoidValve

SampleIn

CheckValve

FeedPump

FilterCoalescer

ExhaustPump

CheckValve

PCI 108.04 128

Precision Scientific Pipeline Flash Point Monitor Model 44620

Figure 43

2= Denotes Relief Valve & Setting (kg./cm )5.0

Solenoid

PSDCatalog44807

FlashPointer

SolenoidSample

FeedPump Check

Vent FlameArrester

CalibrationValve

FilterCoalescer

StandbyReservoir

ExhaustPump

AirCompressor

Bleed Valve

Solenoid

SampleOut

CheckValve

35Solenoid

BleedValve

MechanicalRefrigeration

PCI 108.04 129

Carlo Erba Flash-o-Matic Series 250 Flash Point Analyzer

Figure 44

PCI 108.04 130

Configuration of Flash Point Analyzers

• Analyzers that duplicate ASTM Test Methods• Analyzers that correlate with ASTM Test

Methods

PCI 108.04 131

Rotork Analysis (Hone) Flashar Flash Point Analyzer

Figure 45

Detector HousingTemperature Sensor

Purge Air to Power PackTerminal Box and Control Box

Flowmeter

Heat Exchangerand Drain Pipe

FilterAir

SampleHeater

PurgeAir

MixingChamber

HeatedDetectorHousing

Flash UnitBox

Air PreheatCoilOverflow Chamber

Flash Point Thermocouple

FlameTrap

FlowmeterPressureRegulator

SampleInlet

Sampleto Drain Cal.

Sample

PCI 108.04 132

PCI 108.04 133

PCI 108.04 134

PCI 108.04 135

PCI 108.04 136

Figure 46

Flash point AT Kerosene

Diesel Fuel

Light Gas Oil

Heavy Gas Oil

Top Pumparound

Middle Pumparound

Bottom Pumparound

No. 1 S/S Stripper

No. 2 S/S Stripper

No. 3 S/S Stripper

No. 4 S/S Stripper

Steam Crude Feed

Flash Zone

O/H Condenser

To Fuel Gas

Reflux Drum

Reflux

Straight Run Naptha

PCI 108.04 137

Sample Handling System for a Flash Point Analyzer

Figure 49

Sample Return

Sample Tap

Fast Loop

Fast Loop Flowmeter

Fast Loop Filter

Lab Sample

Sample Cooler

Coolant Pressure Regulator

Dual Filter-

Coalescer System

Water to Drain

Secondary Bypass

To Sample Recovery System

PCI 108.04 138

Perform Exercise 4

PCI 108.04 139

Exercise 4 Key

Figure 90

PressureRegulator

SampleCooler

Coolant

SampleReturn

SampleTap

FastLoop

Fast LoopFlowmeter

FastLoopFilter

LabSample

PointTo SampleRecoverySystem

AnalyzerFlowmeter

Flash PointAnalyzer

VISCOSITY ANALYSERS

PCI 108.04 141

Evaluating Viscosity Analyzers

• Function - to measure the viscosity of a process stream in order to monitor a product specification or to provide data for advanced process control.

PCI 108.04 142

- Crude Distillation (Bottoms residue - Vacuum Tower Side streams)

- Fuels Blending- Lube Oil Production

PCI 108.04 143

• Function• General Applications• Process Analytical Techniques for Viscosity

Measurement– Principles of Operation

PCI 108.04 144

Friction in Solids

Figure 50

InclinedPlaneF

f=Mg Sin & F=Mg Cos Coefficient of Friction = f/F = Tan

PCI 108.04 145

Friction in Fluids - Viscosity

Dynamic Viscosity in Poise is the force needed per unit area to maintain a velocity difference of 1 cm/sec between layers of fluid 1 cm apart

PCI 108.04 146

Friction in Fluids - Viscosity

Dynamic Viscosity in Poise is the force needed per unit area to maintain a velocity difference of 1 cm/sec between layers of fluid 1 cm apart

Force = Dynamic Viscosity * Area * Velocity Distance

Dynamic Viscosity = F * d Ns/m2

PCI 108.04 147

Kinematic Viscosity

KinematicViscosity()

DynamicViscosity()Density()

Unit of Measurement Stokes or Centistokes

PCI 108.04 148

The Nature of Fluid Flow

PCI 108.04 149

The Effect of Temperature on Viscosity

V = Specific VolumeT = TemperatureA & B = Constants

Viscosity of liquids decreases with temperatureViscosity of gases increases with temperature

PCI 108.04 150

CLASSICAL METHODS OF MEASURING VISCOSITY

• Capillary Method - Poiseuille’s• U Tube Method• Rotating Cylinder Method• Falling Sphere Method - Stoke’s

PCI 108.04 151

Classical Methods - Capillary - dp TypePoiseuille's Method of Viscosity Measurement

Hagen - Poiseulle

Absolute Viscosity = Shear Stress = PR/2LShear Rate 4Q/ R3

= P R 4

8 Q LP = Pressure differential across fluid in tube

R = Radius Inside Tube

L = tube Length

Q = Volumetric rate of fluid

PCI 108.04 152

Classical MethodsU-Tube Method of Viscosity Measurement

Figure 53

Constant Temperature Bath

PCI 108.04 153

Classical MethodsRotating Cylinder Method

Figure 54

PCI 108.04 154

Classical MethodsStokes' Method of Viscosity Measurement

Figure 55

Sphere

Radius Velocity Denisty

Fluid ( Density ) d

PCI 108.04 155

Measurement– Principles of Operation– Configuration of Viscosity Analyzers

PCI 108.04 156

Configuration of Viscosity Analyzers

• Capillary DP Type (Poiseuille Method)

PCI 108.04 157

Process Viscometer - CAPPILARY TYPE Precision Scientific Model 41070

Figure 59

Sample out,3/8 NPT

TransmitterConnections(Typical)

Sample in, 1 /2 NPT

Coolant in , 1/4 NPT

Sample out, 1/2 NPT

Electrical,1/2 NPT

Drain,1/2 NPT

Fast LoopSample In

SpentSampleOut

Low TemperatureInterlock Swi tch

Filter

ASTMThermometer

Coolant

TemperatureController

PressureDrop Tube

HighTemperatureShut-down

Fast LoopSample Out

PrimaryHeat Exch.

Secondary Heat Exch.

Gear Pump

PCI 108.04 158

Process Viscometer- CAPPILARY TYPERotork Analysis - Ludlum Sysco Model 1070

Range - By Capillary Selection Max: 0-2500cP Min: 0-5cP

Repeatability: +/- 0.5% FSPrecision: +/- 1.0% FSResponse time: up to 3 minutes

PCI 108.04 159

Process Viscometer- CAPPILARY TYPE Precicion Scientific Model 44860

Figure 60

T/C E/I

Electrical ControlHousing

Air In

Coolant

SampleIn

Strainer

CheckValve

Purge Air Remote Readout(Optional)

0 - 10 VDC

4 - 20 mA DC

Thermometer(Optional)

PressureRegulator

Overflow

FeedPump50 LPH

BoosterPump75 LPH

SampleOut

SeeNote 2

400 psigRelief

Capillary

Thermoswitch

PCI 108.04 160

Process Viscometer- CAPPILARY TYPE Precision Scientific Model 44860

RT Refinery - Plant 52 Diesel Blender

Range: 2- 4000cP by selection of one of 13 capillaries

Accuracy:Correlations with labs +/- 1%Repeatability: +/- 0.5% FSResponse: 2 to 3 minutes

PCI 108.04 161

• Capillary DP Type (Poiseuille Method)• Vibrational Type

- ABB Model 1800 Viscometer- Dynatrol 900 Series Viscometer

PCI 108.04 162

Process Viscometer - Vibrating ElementABB Process Analytics Ultraviscoson

Figure 61A

Legend

Switching Circuits

Viscosity InformationStandard systemwith multiprobeoption

MultipointUnit

1800 UVControl Recorder

2 3 4 5 6

Standard system withautomatic temperaturecompensation option

AutomaticTemperature

CompensationCircuitry

1800 UVControl Recorder

TemperatureCompensation

ViscosityProbe

PCI 108.04 163

Process Viscometer - Vibrating Element ABB Process Analytics Ultraviscoson

Figure 61B

Standard Proces Probe – Standard immersion length

Junction Box

3/4 NPT GuardMountingFitting

HermeticSeal

P/N 631761

3/4 NPT ProbeMountingFitting

Probe Guards

P/N 630508Round Slotted Probe Guard

P/N 630624Flat Plate Probe Guard

Standard Proces Probe – For heavy duty applications

P/N 6306013/4 NPT

Junction Box

3/4 Pipe

Hermetic Seal1 1/4 NPT ProbeMounting Fitting

Standard Proces Probe – For applications where flangemounting is required

3/8 NPTHermeticSeal

3/4 Pipe

P/N 630600

JunctionBoxImmersion

Length

PCI 108.04 164

Process Viscometer - Vibrating Element Automation Products Dynatrol 900 Series

Figure 62

Pickup End Drive Coil Driver

Soft Iron Stator

Drive Armature

Node Point

3/4" N.P.T.

1/2" Conduit

Detector

Temperature Element

Converter

Recorder Controller (User furnished)

Detector

Converter

Recorder Controller (User furnished)

*Note: Mid-ranges also available.

1 10 100 1K 10K 100K 0

Viscosity-Centipoise

PCI 108.04 165

Process Viscometer - Vibrating Element Nametre Vibrating Sphere Viscometer

Figure 63

PrecisionAmplitudeMonitoring

Circuit

Phase Shifterand

Attenuator

SquaringAmplifierOperational

Rectifierand

Low Pass Filter

Display and/orRecording Device

AmplitudeReference

CircuitPre-

Compliant StainlessSteel Sheath

Driver Detector

Driver Shaft

Liquid LevelGroove

Shear Wave

Oscillatory Member

GainControlledAmplifier

PCI 108.04 166

• Capillary DP Type (Poiseuille Method)• Vibrational Type• Rotating Disc Type (Torque Measurement)

PCI 108.04 167

Process Viscometer - Rotating Element Brookfield Model VTA120 Process Viscometer

Figure 64

PCI 108.04 168

Brookfield Model TT 100 In-Line Process Viscometer - Ras Tanura Refinery Plant 52

Figure 65

PCI 108.04 169

Contraves Model DC-43 Process Viscometer

Figure 66

Junction Box onlyin case of explosion-proof design

ConnectionCable

Cooling waterconnection inletand outletG 1/4". Casingjacket must beordered separately

Separate thread hereprior to welding

PCI 108.04 170

Eurcontrol Model VISC-21 Process Viscometer

Figure 67

1 7 2 3 4 5

8 9 10 11 10 12 6

1. Electric Motor 2. Angular Contact Ball Bearings 3. Drive Shaft 4. Mechanical Seal 5. Measuring Vessel 6. Rotating Disc

7. Support Bracket 8. Measuring Disc (Stationary) 9. O-Ring Seal 10. Angular Contact Ball Bearing 11. Measuring Shaft 12. Transducer Cover

PCI 108.04 171

Brabender Convimeter Process Viscometer

Figure 68

1. Protection Sheath 2. Cylindrical Sensing Device 3. Conical Mantle 4. Metal Bellows 5. Drive Shaft 6. Differential Gear 7. Metering Spring 8. Inductive Transducer 9. 2-Speed Synchronous Motor10. Removable Cover

SchematicDiagram

Measuring Head

Flow in Protection Sheath

PCI 108.04 172

• Capillary DP Type (Poiseuille Method)• Vibrational Type• Rotating Disc Type (Torque Measurement)• Falling Piston Type (Stoke’s Method)

PCI 108.04 173

Norcross Falling Piston Viscometer - Operating Principle

Figure 69

Filling Phase

Piston Rod (Attached to

Lifting Mechanism)

End of Measuring Phase

Piston Raised

Tube Opening

Measuring Tube

Piston Bottomed

PCI 108.04 174

Norcross Model M-36 Process Viscometer

Figure 70

3/8" NPT Inlet

3/8" NPT Outlet

Sample Flow Valve

(Adjustable)

Upper Magnet

Piston Position Indicator

Primary Flow

Piston

Lower Magnet

Proximity Switch

Screen

Sam- ple Flow

Sample Solenoid Valve

PCI 108.04 175

• Capillary DP Type (Poiseuille Method)• Vibrational Type• Rotating Disc Type (Torque Measurement)• Falling Piston Type (Stoke’s Method)• Electromagnetic Type

PCI 108.04 176

Cambridge Applied Systems Process Viscometer

Figure 71

Temperature Probe

Slde-Ring

1/2" NPT

Immersion Viscosity Sensor

Slide-Ring Sensor

PCI 108.04 177

PCI 108.04 178

PCI 108.04 179

PCI 108.04 180

PCI 108.04 181

Figure 73

Top Pumparound

Middle Pumparound

Bottom Pumparound

Crude Feed Steam

Flash Zone

O/H Condenser

To Fuel Gas Reflux Drum

Straight Run Naptha

Viscosity

No. 1 S/S Stripper

Steam Kerosene

No. 2 S/S Stripper

Steam Diesel Fuel

No. 3 S/S Stripper

Steam Light Gas Oil

No. 4 S/S Stripper

Steam Heavy Gas Oil

Reflux

PCI 108.04 182

Typical Sample Handling System for a Viscosity Analyzer

Figure 76

Fast Loop

Notes:

All lines and components to be heat traced and insulated. Solvent injection valves to be actuated on loss of temperature in fast loop, (Signal from low temp. alarm).

Low Temp. Alarm

Fast Loop Filters

Sample Tap

Sample Return

Solvent

Lab Sample

To Sample Recovery

To Solvent Recovery

Pressure Regulator

Fast Loop Flowmeter

Solvent

Viscosity Analyzer

PCI 108.04 183

Perform Exercise 5

PCI 108.04 184

Exercise 5 Key

Figure 91

SampleReturn

SampleTap

FastLoop

Fast LoopFlowmeter

FastLoopFilter

LabSample

ViscosityAnalyzer

AnalyzerFlowmeter

PressureRegulator

COLOUR ANALYSERS

PCI 108.04 186

Evaluating Color Analyzers

• Function - to measure the color of a petroleum product or intermediate stream.

PCI 108.04 187

– Fuels Processing

PCI 108.04 188

– Fuels Processing– Heat Exchanger Leakage

PCI 108.04 189

• Function• General Applications• Color Measurement

– Principles of Operation

PCI 108.04 190

Typical Chromophoric Groups

Figure 77

Chromophore Group ExampleEther O C2 H5 O C2H2

Thioether S CH3 S CH3

Amine NH2 CH3 NH2

Mercaptan SH C2H5 SH

Alkyne CC CHC CH2 CH2

Aldehyde CHO CH3 CHO

Alkene CC CH3 CCH2

Alcohol OH C2H5 OH

Ketone CO (CH3)2CO

Nitro-compound NO2 CH3 NO2

Azo-compound NN CH3 NN CH3

Benzene

Napthalene

Anthracene

(–C = C–)n

PCI 108.04 191Figure 78

Relationship Between Wavelength and Color

Wavelength (nm) Transmitted Color Complementary Hue

<380 Ultraviolet

380-435 Violet Yellowish-green

435-480 Blue Yellow

480-490 Greenish-blue Orange

490-500 Bluish-green Red

500-560 Green Purple

560-580 Yellowish-green Violet

580-595 Yellow Blue

595-650 Orange Greenish-blue

650-780 Red Bluish-green

>780 Near infrared

PCI 108.04 192

Spectral Response of Color Standards

Figure 79A & B

400 500 600 0

Wavelength

APHA 20

APHA 15

APHA 10

400 500 600 0

Wavelength

SAYBOLT 14.3

SAYBOLT 19.4

SAYBOLT 25.0

PCI 108.04 193

Spectral Response of Color Standards

Figure 79C

400 500 600 700 800 0

Wavelength

ASTM 1

ASTM 2

ASTM 3

ASTM 4

ASTM 5

ASTM 6

PCI 108.04 194

• Function• General Applications• Process Analytical Techniques for Color

Measurement– Principles of Operation– Configuration of Color Analyzers

PCI 108.04 195

Customs Sensors & Technology Model 5520 Color Analyzer

Figure 80A

Splitter

Measuring Filterand Detector

Reference Filterand Detector

LightSource

Analyzer

Fiber-Optic Cables

Sample Cell

Elec-tronics

Internal Reference

Splitter

Measuring Filterand Detector

Reference Filterand Detector

LightSource

Analyzer

Fiber-Optic Cables

Sample Cell

External Reference

Elec-tronics

PCI 108.04 196

Customs Sensors & Technology Model 5520 Color Analyzer

Figure 80B

PCI 108.04 197

Precision Scientific Model 42015 Colorimeter

Figure 81

AlarmRelay

Power Supply

Power Alarm Module

SampleOut

SampleIn

OpticalFillers

Control/Display Module

Lamp DigitalPCB

Display

Fiber Optic Source Photodiodes

4/20 mA

AnalogPCB

DetectorFlow Cell

Source

Flow Cell Enclosure

PCI 108.04 198

Precision Scientific Model 42015 Colorimeter

ASTM D1500 SAYBOLT D-156

Max Temperature: 55CSam Pressure: 147psig 1470psig@ 150CSam Temp: -20 to 150CClass1, Division 1, B,C&D

PCI 108.04 199

Rotork Analysis Model 7613 Color Alarm

Figure 82

PowerSupply

SupervisoryCircuit

AlarmRelay

Meas.Store

Gating

ComparatorPhoto diode

SampleCell

ChoppingDisc

TungstenLamp

Twist-to-Test

Filter

Ref.Store

PCI 108.04 200

PCI 108.04 201

PCI 108.04 202

Evaluating Color Analyzer

PCI 108.04 203

Evaluating Color Analyzer

PCI 108.04 204

Figure 83A

Top Pumparound

Middle Pumparound

Bottom Pumparound

Atmospheric Pipestill

Straight Run Naptha

Crude Feed Steam

Flash Zone

O/H Condenser

To Fuel Gas Reflux Drum

Reflux

No. 1 S/S Stripper

Steam Kerosene

No. 2 S/S Stripper

Steam Diesel Fuel

No. 3 S/S Stripper

Steam Light Gas Oil

No. 4 S/S Stripper

Steam Heavy Gas Oil

PCI 108.04 205

Figure 83B

PCI 108.04 206

Typical Sample Handling System for a Color Analyzer

Figure 86

PressureRegulator

SampleCooler

Coolant

SampleReturn

SampleTap

FastLoop

Fast LoopFlowmeter

FastLoopFilter

LabSample

FilterCoalescer

Water +Sample toRecovery

To SampleRecovery

AnalyzerFlowmeter

Bypass/IsolationValves

PCI 108.04 207

Perform Exercise 6

PCI 108.04 208

Exercise 6 Key

Figure 92

SampleReturn

SampleTap

FastLoop

Fast LoopFlowmeter

FastLoopFilter

LabSample

Point To SampleRecovery

ColorAnalyzer

PressureRegulator

PCI 108.04 209

Perform Evaluation

PCI 108.04 210

Evaluation Key

Figure 93

SampleReturn

FastLoop

Fast LoopFlowmeter

FastLoopFilter

LabSample

SampleCooler

Coolant

PressureRegulator

DualFilter-Coalescer

System

Water toDrain

SecondaryBypass

PCI 108.04 211

Pour Point

Physical Property Analyzers

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