UE One Series Seal Oil Skid Cost Reduction

UE ONE SERIES APPLICATION NOTE
One Series electronic switch reliably protects generator with I Am Working^TM

A major electrical infrastructure company designs and manufactures power generation turbines that use natural gas, oil, coal and other fuel technologies. The company has standardized on One Series model 2XLP43 for measuring gage and differential pressure to replace traditional transmitters, UEmechanical switches and mechanical gauges on their seal oil skids.



THE PROBLEM:
The company needed to lower costs, reduce maintenance and provide more reliable hydrogen-cooled generators for their customers worldwide. In order to monitor pressure remotely, provide switch control and be able to instantly view pressure readings, three discrete instruments were needed – a pressure transmitter, a pressure switch and a local gauge. These three instruments were all connected to the same pressure source using the piping tree arrangement to the right.

Counting all of the tubing, elbows, t-fittings and connections to each instrument and the pressure source, potential leak paths quickly became a problem. Not counting block and bleed valves, there were a minimum of 12 threaded connections where the media could leak. The cost of the stainless steel tubing and fittings, the cost of the labor to plumb and leak-test and the maintenance required should clogging or leaking occur were all considered. Adding in the cost of the instrumentation and considering reliability, clearly a better method was needed.

THE SOLUTION:

The company needed a highly reliable instrument that could evaluate and report its own health status and provide the functions of the three instruments while reducing overall costs. The One Series 2XLP model is primarily a smart pressure transmitter with display that includes a programmable electronic switch – switch + gauge + transmitter all-in-one.

All One Series models include a self-diagnostic feature called I Am WorkingTM that monitors several vital instrument functions and reports health status three ways – locally on the digital display and remotely via the 4-20 mA analog and using discrete switch signals.

The One Series’ I Am WorkingTM feature watches for potential faults that could render the device unreliable. Unlike other blind instrumentation, the One Series can report detected faults with its own imbedded software, keypad, watchdog timer, power, switch and sensor. For example, if a clog occurs in an impulse line connected to the pressure sensor, the One Series can detect and report this fault before it becomes a larger problem – an undetected fault. In this case, the display will read “PLUG” while the switch opens (fail safe) and the 4-20 mA output saturates to 24 mA. The PLC evaluating these outputs then initiates an alarm or emergency shutdown, as appropriate.

For the company, the One Series carries worldwide hazardous location approvals and the units of measure are field adjustable, so no matter where in the world these seal oil skids land, the units of measure can be set to the local preference during commissioning. Reliability data is provided by a third-party failure modes and effects diagnostic analysis (FMEDA) report, available on UE’s website.

If you would like more information, pricing and availability on the UE One Series Switch or other United Electric Controls products please contact Forberg Scientific Customer Service.
Tool Free: 855-288-5330
Email: mechanicalsales@forberg.com

How to Select a UE Pressure Switch

United Electric Controls (UE), a market leader in pressure switching technologies with hundreds of permutations for diverse applications in virtually every industry has spawned unintended consequences for users - too many models to choose from. The upshot of this is a simple reliable switch is most likely available for your application. All you need to do is follow the recommendations below and have UE select the ideal switch for your needs.

How to Select a Pressure Switch

Pressure switches are widely used by many industries and within many applications. The basic function of a pressure switch is to detect a pressure change and convert it into an electrical signal function – typically on/off or off/on. Pressure switches may be of electro-mechanical or electronic/solid-state design; and while each may have its advantages, arriving at the correct pressure switch for your application is the same.

Set point & deadband

Application set point is the desired value reached at rising or falling pressure at which the micro-switch changes electrical states. Depending upon the pressure switch function, the micro-switch could be wired to open or close when set point is achieved thereby triggering an event such as an alarm, equipment shutdown, or powering up secondary equipment. Ideally the set point should fall into the mid 50% of the pressure switch range for best performance including repeatability and long life. On an electro-mechanical pressure switch, set point may be adjusted internally or externally either through blind adjustment or reference dial. An electronic pressure switch would have internal or external adjustment via a key pad and digital display.

Deadband is the on-off differential required to reset the micro-switch. This value may be fixed or adjustable with an electro-mechanical switch and may be up to 100% adjustable on an electronic switch. Deadband may be an important factor to consider depending upon the application requirements.

System pressure

Knowing your normal and maximum system pressures will help in selecting a pressure switch with appropriate minimum and maximum operating parameters. Once your set point is established, other factors to consider are vacuum and/or surge pressure that could affect switch operation. This would involve maximum working pressure, over range pressure, and proof pressure specifications of a pressure switch. The relationship between set point and system pressure has a direct effect on switch performance and life.

Electrical considerations

Micro-switches are available in a variety of configurations. The most common for electro-mechanical pressure switches is 15A, 480VAC SPDT (single pole, double throw). The advantage of a SPDT micro-switch is that it offers wiring flexibility to either open or close on pressure change. Other micro-switches available include 1A with gold contacts, useful when working with a PLC, or at the upper end, 30A when switching certain high voltage heaters or motors. Adjustable micro-switches help with deadband adjustment. A DPDT (double pole, double throw) micro-switch would provide two simultaneous functions off of one micro-switch. If a low-high limit alarm and shutdown were required, there are pressure switches that include two SPDT micro-switches that are independently settable.

An electronic pressure switch would use solid-state relays to change states. Like an electro-mechanical switch, the electronic switch can be programmed to open or close on rising or falling pressure. There are different capacities for switching voltage and current depending upon the application requirements.

Process media and wetted parts

The pressure connection and sensor are known as wetted parts since they come into direct contact with the process media. Sensor material is either elastomer (i.e. Buna-N, Teflon®) or metallic (i.e. Brass, Stainless Steel) with metallic or composite pressure connections. The process media must be compatible with the wetted parts material. Process media temperature should also be considered as each of the different wetted materials would have differing operating properties. 

Pressure switch mounting

If the unit is to be installed directly onto the process, there are many methods of installation. Typically a 1/8”, 1/4”, or 1/2” NPT (national pipe thread taper) connection is used with a mating fitting to secure the pressure switch to the process. There are also straight threaded (SAE, BSPT) connections, flush mount connections, and sanitary connections. The pressure switch may be mounted directly in the process line using the threaded connection, a manifold, or flange; or the enclosure could be bolted to a mounting plate or other plane to secure it. If heavy vibration is present, you may choose to use a remote diaphragm seal with the pressure switch. The diaphragm seal mates with the process connection while the pressure switch enclosure is mounted securely away from the vibration.

Process environment

It is important to know what type of environment the pressure switch would be installed in – hazardous or ordinary location; indoors or outdoors; exposed to salt air; inside a control panel; in high ambient temperature. These are just some of the factors to consider so the right enclosure type is chosen. Enclosure types come in many shapes, sizes, and materials. They also conform to various industry and third-party approval standards. Electronic switches can be used to replace electro-mechanical switches when SIL is needed for safety applications. There are also electro-mechanical pressure switches without enclosures; typically used in OEM, non-hazardous locations where the environment is benign.
With careful consideration of all the factors listed above, choosing a pressure switch is a snap.

Visit United Electric Controls (UE) Product Selector to find your pressure switch.

If you would like more information like pricing and availablity about United Electric Controls (UE) Pressure Switches or other UE products please contact Forberg Scientific customer service.
Toll Free: 855-288-5330
Email: mechanicalsales@forberg.com

United Electric Controls Pressure & Temperature Plant Safety Solutions

Whether it’s protecting valuable equipment, processes or your loyal employees, creating a safe work environment is a corporate responsibility. Installing safety instrumentation not only protects critical equipment and processes; it also creates a safe work environment for your employees and a healthier environment for us all.

UE’s One Series digital pressure and temperature switch comes with complete Failure Modes, Effects and Diagnostics Analysis (FMEDA) data from Exida, enabling plant safety personnel to reliably calculate Safety Integrity Levels (SIL). The rugged One Series is installed in the field, at the point of critical monitoring, with response times 5X faster than a transmitter, providing immediate, local shutdown, while streamlining wiring and software. For your plant safety requirements, simplify and improve reliability with the One Series for all critical pressure and temperature shutdown applications.

Direct-Acting Safety Shutdown

The rugged and reliable One Series pressure and One Series temperature switch protects equipment, processes and personnel. It is installed where needed, in the field, with direct-acting on/off digital switching. With 0.1% repeatability combinded with solid-state reliability and on-board diagnostics, the One Series is the clear choice for critical plant safety applications.

Faster Response Time Than A Transmitter

Plant safety requires immediate response to dangerous conditions. The One Series response time is 60 mS, five-times faster than a process transmitter. And, with direct switching capability at the point of critical conditions, it provides an alternative technology to the overreliance on transmitters and central control systems, eliminating the possibility of “Common Mode Failure.”

 

ONE SERIES

Electronic Pressure, DP & Temperature Switches

• Fully adjustable set point and deadband

• 5X faster than a transmitter and 50% less installed cost

• Digital display includes process, status and self-diagnostics

• 2-wire and loop-powered 4-20 mA models available

• Measures gage pressure, differential pressure or temperature

• 0.1% repeatability with temperature compensation

• Provides the functions of a switch, gauge and transmitter

• Ranges to 6000 psi (410 bar), 200 psid (13.8 bar), 1000˚F (538˚C)

On-Board Diagnostics

The One Series continually checks health status for circuit and sensor integrity, providing extra assurance that it stands ready to perform when needed. In addition, it provides a “pulsed” output that can be activated to help distinguish a critical alarm or shutdown signal above the frequent control room “noise” of false trip signals that may be ignored or disabled at operator discretion.

Suitable For SIL2 Applications

Request the "EXIDA" Failure Modes, Effects, Diagnostics Analysis (FMEDA) report from UE covering the One Series, enabling you to calculate the Safety Integrity Level (SIL) for your applications. Also request the SIL Verification Summary report to compare the One Series with generic switches and transmitters. Go to www.ueonline.com for copies of these 3rd party reports.

I AM WORKING (IAW):

The Role of Self-Diagnostics in SIS Applications

All One Series electronic switches include powerful self-diagnostics. Critial functions of the One Series are checked during initialization, and then continuously monitored by the IAW® algorithm. Detected faults are reported using three methods of annunciation:

1. The local digital display provides clear fault indications at a glance
2. Each fail-safe switch will open, providing a remote fault indication
3. On models that include 4-20 mA output, the analog signal will indicate 0, 3.5, 22 or 24 mA, depending on the type of fault.

IAW PROGRAMMING MODE AND RESULTING SWITCH STATES

The fail-safe-open IAW® programming mode provides a predictable annunciation that differentiates between an upset process variable and a detected fault using a single discrete “switch” output.

• When process and instrument conditions are normal, the One Series switch is pulsed, sending out a continuous heartbeat signal that is easily detected by the safety PLC.
 
• When the process variable reaches the programmed set point, the One Series switch will close, indicating that the process is upset but the One Series remains functioning (no faults detected).
 
• If the switch opens, this condition indicates a fault detected by the IAW® self-diagnostics. The reporting scheme also accounts for wiring integrity. If a wire is broken or power is lost, this type of “fault” would also appear as an open switch to the safety PLC.

For more infromation on how the One Series from United Electric Controls can maximize your plant safety efforts please contact Forber Scientific, Inc. customer Service

Toll Free: 855-288-5330

Email: mechanicalsales@forberg.com

Vist: www.forberg.com

 

Diaphragm Seal & Chemical Seal Operating Principle

The drawing below illustrates the operating principle of a diaphragm seal assembly. A pressure measurementinstrument such as a conventional pressure gauge or electronic pressure transmitter is either mounted directly to the diaphragm seal or attached to the seal by means of a capillary or cooling element.
A diaphragm within the diaphragm seal separates the gauge / transmitter from the process medium. Any part of the diaphragm seal (i.e., diaphragm, lower housing, gaskets) which will be exposed to the process medium is selected from materials resistant to pressure, temperature and possible chemical attack by the process medium.

The diaphragm seal is also filled with a transmitting fluid or system fill fluid. Any pressure applied by the process medium to the seal diaphragm is hydraulically transmitted to the pressure element of the gauge / switch / transmitter thus generating a pressure reading.

If you would like additional information about WIKA Diaphragm Seals or other WIKA Products please contact Forberg Scientific, Inc.
Toll Free: 855-288-5330
Email: mechanicalsales@forberg.com

Diaphragm Seal or Chemical Seal Application

Diaphragm seals, also referred to as chemical seals, are used to isolate pressure gauges, switches, and transmitters from clogging and/or corrosive media. Standard diaphragm seal bodies and diaphragms are made of stainless steel; however, a variety of materials from carbon steel to Hastelloy® C-276 are available to meet the demands of most applications. WIKA diaphragm seals can operate in pressure applications from 10" H2O to 20,000 psi and media temperature between -130°F and 752°F.

EXAMPLES OF TYPICAL DIAPHRAGM SEAL APPLICATIONS

• The media is corrosive and may damage a sensitive element such as a Bourdon tube gauge, pressure switch or transmitter diaphragm.
• The temperature of the media may be too high for a standard gauge, switch or transmitter to operate properly.
• The media is highly viscous or tends to crystallize, or polymerize and may clog the pressure port of a gauge, switch or transmitter.
• The media is non-homogenous or contains suspended matter such as wood pulp which may clog the pressure port of a gauge, switch or transmitter.
• Remote reading is required. A diaphragm seal with a capillary line will allow remote installation of a pressure instrument.
• The sanitary cleanliness level is critical. A flush mounted or INLINE SEAL™ sanitary type diaphragm seal avoids dead space and cavities.
• The media is toxic or hazardous and may pollute the environment. A suitably designed diaphragm seal will provide additional protection.
• The application requires high overpressure protection. A diaphragm seal with a contoured diaphragm bed can be configured to provide overpressure protection and protection to the instrument.

WIKA diaphragm seal systems are an excellent value and offer savings by:

• Meeting fugitive emission requirements
• Extending the service life of the pressure instrument
• Reducing the cost of installation
• Reducing or eliminating maintenance costs

If you would like additional information about WIKA Diaphragm Seals or other WIKA Products please contact Forberg Scientific, Inc.
Toll Free: 855-288-5330
Email: mechanicalsales@forberg.com

UE ONE SERIES low cost mechanical switch

Forberg Scientific Offers the United Electric ONE SERIES, which has all the reliability of an electronic transmitter, with the ease of use and low cost of a mechanical switch!

MAKE THE SMART CHOICE. THE ONE SERIES FROM UE IS:

• A reliable, cost-effective solution for upgrading plant instrumentation.
• Ideal for applications that demand a switch that never needs calibration, has programmable adjustability and 0.1% repeatability.
• Easily integrated into a safety instrumented system (SIS) that requires a smart-diagnostic switch (FMEDA and SIL verification reports available upon request).



KEY FEATURES THAT SET UE’s ONE SERIES APART:
• Digital process display
• Programmable set point and deadband
• Self-diagnostic solid-state digital electronics
• Plug port detection
• Nuisance trip filtering
• Patented electronic IAW self-diagnostics
• Min/Max process values memory
• 3-year warranty

APPLICATION VERSATILITY:
For alarm and shutdown switching applications, there is no better choice than the One Series family of electronic switches from United Electric Controls. Measuring gauge pressure, differential pressure or temperature, the extremely rugged and reliable One Series takes all of the guess-work out of monitoring process variables to prevent injury, loss and downtime. With its large digital display, fully-adjustable deadband, and 100% solid-state design, the One Series is the obvious choice for plant upgrades and new construction projects. A built-in microprocessor includes digital repeatability and intelligent self-diagnostics, offering plant operators an extremely reliable and smart protection device.

Proven in use in literally thousands of diverse applications, UE has recently developed explosion-proof One Series models, extending this revolutionary switching technology to Zone 1 (Division 1) areas.

PROVEN IN LITERALLY THOUSANDS OF DIVERSE APPLICATIONS! HERE ARE JUST A FEW
• Pumps and compressors- start/stop, optimizing, shutdown, staging
• Lubricating oil monitoring- sump temperature, bearing pressure, predictive maintenance
• Hydraulic oil pressure- high pressure monitoring, emergency shutdown, ram cycling
• Filter monitoring- automatic backwash, clog and change indication, proving flow
• Safety systems- safety integrity levels 1 & 2, alarm and shutdown, local switching, fast response time
• Plant upgrades- power and wastewater plant upgrades, drop-in replacement for mechanical switches

More information about the UE One Series click UE One Series Catalog

If you would like more information about the UE One Series or other United Electric Controls items please contact Forberg Scientific, Inc Customer Service Representative.
Phone: 248-288-5330
Email: mechanicalsales@forberg.com

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GO Switch Leverless Limit Switch

GO Switches are now available for Forberg Scientific Inc.

GO Switch "leverless limit switches" provide reliable, durable position sensing in the most demanding plant conditions. Unlike mechanical limit switches or inductive proximity sensors, GO Switches use a unique hybrid technology that elimainates wear and tear. As a result, GO Switches are more dependable and last longer in the toughest applications. These switches are in stock and available for immediate delivery at www.forberg.com.

GO Switch Differance

Unique hybrid technology. GO Switch have a one-of-a-kind "leverless limit switch" design that combines the advantages of existing limit switch and proximity sensor technologies. As a result, GO Switch deliver better performance in the most demanding applications.

Reliability in a variety of industries. For over fifty years, GO Switch have set the standard for mission-critical position sensing in the automotive, cement, chemical, diecasting, food & beverage, hydrocarbon, manufacturing, mining, oil & gas, petrochemical, power generation, pulp & paper, steel & aluminum, tire & rubber, and water & wastewater industries.

Durability when it matters most. GO Switch last longer in plant conditions that are hot, cold, wet, dirty, abusive, corrosive, and explosive. A wide variety of GO Switches are cerified for use in all hazardous areas including Zone 0 ( intrinsically safe ), Zone 1 ( explosion proof ), and Zone 2 ( non-incondive ). With no exposed moving parts and no delicate electronics, GO Switches have been designed to withstand caustics, corrosives, salt water, submersion, physical abuse, vibration, and temperatures ranging from -58F / -50C to 400F / 204C. All types and varieties of GO Switches are available for online purchase at www.forberg.com .

Customer Service

Toll Free: 855-288-5330

Email: mechanicalsales@forberg.com

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Forberg Scientific introduces newly expanded Technical Support section

Forberg Scientific recently announced the expansion of its technical support section of its website ( http://www.forberg.com/ ). The technical support section has a variety of resources available including:

1. Tube Fitting Installation Instructions


2. Tubing Selection Instructions


3. Fluid and Gas Material Compatibility Information


4. Pressure Unit Conversion Table


5. How to Select a Pressure Gauge


6. Pressure Gauge Installation Instructions


7. Pressure Gauge Calibration Instructions


8. How to Select a Pressure Sensor

Forberg Scientific also offers real-time on-line chat services to help answer customer questions and aid in product selection for stainless steel fittings, pressure gauges, instrumentation valves, temperature gauges, speed sensors, filtration, stainless steel tubing, process automation products, heat trace, pressure and temperature switches.

UE One Series Sensors: Durable, Reliable & Versatile

United Electric Controls' One Series electronic pressure switches & temperature switches. United Electric Controls (UE) is renowned for high-quality workmanship and product design, and the One Series carries this nearly 80-year traditon well beyond electromechanical swithes. UE's One Series line of digital electronic pressure switches and digital electronic temperature switches sets new standards for quality, reliability and versatility. Designed to meet the needs of harsh and hazardous applications the One Series' advanced self-diagnostics and digital electronics provide the most reliable switches for a variety of diverse industries. The One Series from UE allows you to choose from explosion-proof, intrinsically safe and non-incendive modles that monitor gauge pressure, differential pressure or temperature. With up to two fully adjustable set points and deadbands, available 4-20 mA analog output, and absolutely no moving parts, these versatile instruments can now be used in a wide variety of applications where switches weren't previously considered. Featuring a solid-state design, UE's One Series is your best choice for tough applications with high cycle rates, vibration and shock. For plant upgrades, there are a variety of power optionsranging from 2-wire discrete and analog loop-powered models to externally powered models that can deliver up to 280 VAC at 10 amperes to the load. With an integral digital display and 4-20 mA output, the One Series from UE can effectively do the job of three - replacing a switch, a gauge and a transmitter. Powerful yet easy to install, the Ones Series from UE features tamper-resistance, intuitive programming, and set-up that is fast and easy.

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