Inst ToolsInst ToolsInst Tools
  • Courses
  • Automation
    • PLC
    • Control System
    • Safety System
    • Communication
    • Fire & Gas System
  • Instrumentation
    • Design
    • Pressure
    • Temperature
    • Flow
    • Level
    • Vibration
    • Analyzer
    • Control Valve
    • Switch
    • Calibration
    • Erection & Commissioning
  • Interview
    • Instrumentation
    • Electrical
    • Electronics
    • Practical
  • Q&A
    • Instrumentation
    • Control System
    • Electrical
    • Electronics
    • Analog Electronics
    • Digital Electronics
    • Power Electronics
    • Microprocessor
  • Request
Search
  • Books
  • Software
  • Projects
  • Process
  • Tools
  • Basics
  • Formula
  • Power Plant
  • Root Cause Analysis
  • Electrical Basics
  • Animation
  • Standards
  • 4-20 mA Course
  • Siemens PLC Course
Reading: Unreliable Ammonia Flow Transmitter Reading and Problems
Share
Font ResizerAa
Inst ToolsInst Tools
Font ResizerAa
  • Courses
  • Design
  • PLC
  • Interview
  • Control System
Search
  • Courses
  • Automation
    • PLC
    • Control System
    • Safety System
    • Communication
    • Fire & Gas System
  • Instrumentation
    • Design
    • Pressure
    • Temperature
    • Flow
    • Level
    • Vibration
    • Analyzer
    • Control Valve
    • Switch
    • Calibration
    • Erection & Commissioning
  • Interview
    • Instrumentation
    • Electrical
    • Electronics
    • Practical
  • Q&A
    • Instrumentation
    • Control System
    • Electrical
    • Electronics
    • Analog Electronics
    • Digital Electronics
    • Power Electronics
    • Microprocessor
  • Request
Follow US
All rights reserved. Reproduction in whole or in part without written permission is prohibited.
Inst Tools > Blog > Root Cause Analysis (RCA) > Unreliable Ammonia Flow Transmitter Reading and Problems

Unreliable Ammonia Flow Transmitter Reading and Problems

Instrumentation engineering root cause analysis of unreliable ammonia flow transmitter reading and problems.

Last updated: September 28, 2022 2:55 pm
S Raghava Chari
Root Cause Analysis (RCA)
No Comments
Share
4 Min Read
SHARE

Instrumentation engineering root cause analysis of unreliable ammonia flow transmitter reading and problems.

Contents
Unreliable Ammonia Flow Transmitter ReadingTarget Flow Transmitter Brief ExplanationBenefits Derived
Article Type:Root Cause Analysis (RCA)
Category:Instrumentation
Equipment Type:Sensors
Author:S. Raghava Chari

Note: This root cause analysis (RCA) is from real-time scenarios that happened in industries during the tenure of two or three decades ago. These articles will help you to improve your troubleshooting skills and knowledge.

Unreliable Ammonia Flow Transmitter Reading

6 Nos. of orifice and DPT flow meters measuring around 3-bars; near 00 C liquid ammonia read erratically. Reliable and accurate flow metering would improve NPK fertilizer production and quality

The Author solution: The process licensor disregarded the author guessed root cause (RC): the stagnating liquid ammonia at 3-bars pressure of 1000 C boiling point boils in the orifice to differential pressure transmitter (DPT) leads; hence, the erratic flow readings. After failed attempts of leads shortening, he suggested buying seal-type DPTs.

The seal instruments’ problems plagued the author rejected it; proposed installing Target Flow Transmitters (TFT, below figure), which requires no process leads would perform reliably.

Target Flow Transmitter Problem
Note: This is a pneumatic instrument

Target Flow Transmitter Brief Explanation

The meter body carried target forms an annular orifice. Flow caused differential pressure across the target exerts a force F on it. The force beam conveys F to the meter body bolted pneumatic transmitting head which outputs 0.2 to 1 bar pneumatic signals proportional to Q2 (Q –> flow rate).

Electronic heads output 4-20 mA current signals. He accepted it and the plant ordered the TFTs.

Benefits Derived

Below listed are the Author Root cause solution benefits:

  1. Target flow meters purchase and installation costs are around 30% of the process licensor proposed seal DPTs, which might not have worked as good as the TFTs or even not at all!
  2. Target flow transmitter do not require any maintenance, they are fit and forget instruments.
  3. Because of no process leads and no evaporation there, Target flow transmitter readings are very reliable with low temperature boiling point liquids as in this case and room temperature congealing liquids ex. Asphalt, molten sulfur etc.
  4. Reliable ammonia flow readings revealing the high ammonia specific consumption figures led to problem study and elimination.
  5. The unreacted ammonia from the former wastefully admitted excess escape into atmosphere. The consequent polluted, pungent and uncomfortable working environs not only affect the persons around but also corrode plant equipment externally besides causing frequent electrical short circuit failures. Target flow transmitter’s enabled eliminating these.
  6. The plant contractor got his final payment

Author: S. Raghava Chari

Do you face any similar issues? Share with us through the below comments section.

If you liked this article, then please subscribe to our YouTube Channel for Instrumentation, Electrical, PLC, and SCADA video tutorials.

You can also follow us on Facebook and Twitter to receive daily updates.

Read Next:

  • Level Transmitters Zero Drifts
  • Pitot-tube Replaced with Orifice
  • Mechanical Temperature Indicator
  • Pressure Transmitter Stopped Working
  • Seal Pressure Instruments Problems
Don't Miss Our Updates
Be the first to get exclusive content straight to your email.
We promise not to spam you. You can unsubscribe at any time.
Invalid email address
You've successfully subscribed !

Continue Reading

Seawater Pipeline Spools from day-1 leaks threaten Plant Shutdown
Doubtful Temperature Readings threatens Soaking Pit Wrecks 
Industrial Light Fittings and Street Light Poles Corrosion Problems
Alternate 110 KV Connection to Feeder A
Gas Cooler Re-tubing Done Successfully (Root Cause Analysis)
Leaky Boiler Drum Level Switch Stops NH3 Plant Commissioning
Share This Article
Facebook Whatsapp Whatsapp LinkedIn Copy Link
Share
Leave a Comment

Leave a Reply Cancel reply

Your email address will not be published. Required fields are marked *

Stay Connected

128.3kFollowersLike
69.1kFollowersFollow
210kSubscribersSubscribe
38kFollowersFollow

Categories

Explore More

Pipeline Shakes Torn apart Valve Positioners
Totally Enclosed Fan Cooled (TEFC) Motors Rampant Winding Burnouts
Finned Tube Steam Leaks – Root Cause Analysis
Multistage Flash Drums Erratic Level Readings
Repeat Safety Valve Popping caused Urea Plant Shutdown
Leaking Plug Valves Pose Safety Hazards and Lead to Plant Shutdown
Transformers Coolers Weld Joints Oil Oozes Were Eye Sores
Rupture Discs bursts caused too many Urea Plant Shutdowns

Keep Learning

Fasteners and General Corrosion of Electrical Motors

Fasteners and General Corrosion of Electrical Motors

Less than 40% available Plant Air Compressors made available 100%

Less than 40% available Plant Air Compressors made available 100% for Operations

Poorly Built Switchgears

Poorly Built Switchgears – Why Breaker Parts Tear apart or don’t work?

Turbine Flow Meter (TFM) Field Calibration

Turbine Flow Meter (TFM) Field Calibration Uncommon Request

Minimum Oil Circuit Breaker (MOCB) Spares & Service

Minimum Oil Circuit Breaker (MOCB) No Vendor Spares & Service

Junction Box Cooler

Junction Box Internal Corrosion Problems and Solutions

Packaging Machinery

Poor Bagging Scale Availability Threatened Production Cuts

Instrumentation Engineering Root Cause Analysis

Instrumentation Engineering Problems Solved – Root Cause Analysis

Learn More

Quiz on Electrical Meters and Measurement

200+ Quiz on Electrical Meters, Measurement, and Troubleshooting

thermal imaging instrument

Thermal Imaging Temperature Measurement

Star-Delta PLC programming with 1 button

How to Program a Star-Delta System using 1 Button in PLC?

Analog Electronics Projects

Analog Electronic Projects for Final Year Engineering Students

Multi Way Switches using PLC

Making Multi Way Switches using PLC

Basic Power Electronics Interview Questions

Basic Power Electronics Interview Questions

Basic PLC Alarm Programming Example

Basic PLC Alarm Programming Example

PLC Scan Time

PLC Scan Time

Menu

  • About
  • Privacy Policy
  • Copyright

Quick Links

  • Learn PLC
  • Helping Hand
  • Part Time Job

YouTube Subscribe

Follow US
All rights reserved. Reproduction in whole or in part without written permission is prohibited.
Welcome Back!

Sign in to your account

Username or Email Address
Password

Lost your password?