Ability to meet any challenge
The chemical industry makes extremely high demands on all instruments used within the process. They are subject to strict international guidelines like the PED and ATEX. Electronic and mechanical measuring instruments for pressure, temperature and level are used for general applications as well as in potentially explosive areas, and must operate as satisfactorily in aggressive environments as in non-aggressive environments. In order to ensure long-term process safety under these difficult circumstances, a regular calibration of the measuring instruments is recommended.
A wide range of industrial processes would not be possible without the production of various chemicals. Fertilizer companies need urea and ammonia. The latter is also used in the manufacturing of synthetic fabrics and dyes, as well as chemical recycling. In addition to ammoniafiber optics fabrication requires chlorinated gas and other chemical vapors. These are just a few examples of the important role that the chemical industry plays in modern life.
Although these processes vary greatly, what they have in common is the demand they place on electronic and mechanical measuring instruments. Many of the chemical compounds used in manufacturing are highly aggressive: acidic, alkaline, potentially explosive, etc. The temperatures and pressure are also extreme. For example in an ammonia reactor, the process can reach as high as 932°F (500°C) and 2,900 psi (200 bar).
Standard Materials and Safety Requirements
Stainless steels are mainly used as standard materials in chemical process technology. The worldwide commonly used materials 316L and 1.4404/1.4435 are generally employed. For chemical processes involving highly-aggressive media, – in combination with diaphragm seals/gauges with diaphragm for pressure measurement, or thermowells for temperature measurement as well as bypass chambers and tubes for level measurement - an extensive range of chemically-resistant materials is available. In this case, all wetted parts are made of this special material.
For most chemical applications, the instrument’s case and wetted parts are made of industrial-grade stainless steel (316L, 1.4404/1.4435). Extremely harsh media call for specialty materials such as Hastelloy®, Monel®, or titanium.
Besides the material, there are other effective ways to safeguard pressure, temperature, and level instruments:
- Diaphragm seals to add a protective layer between the gauge and the media
- Thermowells to shield temperature sensors from the media
- Bypass chambers and tubes for contact-free level measurement
- Reflective flag systems to improve instrument visibility and increase plant safety
Some applications require intrinsically safe or explosion-proof pressure instruments, depending on the type of feedstock and the location of the device. Several regulatory entities – ATEX, PED, IECEx, EAC, CSA – have developed instrument guidelines and standards for chemical processes.
Application Examples
For optimal safety and efficiency, chemical plants need to monitor and control the pressure, temperature, level, and flow of their processes. Measuring instruments are found in the following equipment:
- Ammonia reactors and separators – pressure and temperature
- Buffer, storage, and transportation tanks – pressure and level
- Urea reactors – pressure, temperature, and level
- Gas scrubbers – pressure and flow
- Boilers – temperature, level, and flow
- Condensers – temperature and flow
- Heat exchangers and cooling units – temperature and flow
- Diazotization vessels – temperature and level
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Instrumentation for the Chemical Industry
WIKA is a global leader in the design and manufacturing of high-quality measuring instruments. Our portfolio for the chemical process industry includes the following:
- Temperature – thermocouples, RTDs, thermowells
- Pressure – mechanical gauges, digital gauges, pressure sensors/transmitters, process transmitters, diaphragm seals
- Level – magnetostrictive, optoelectronic, and , bypass level indicators
- Flow – orifice plates, Venturi nozzles, Pitot tubes, flow switches
We also have specialized solutions for chemical applications, such as furnace tubeskin thermocouples, multipoint sensor flexible assemblies, and diaphragm monitoring systems.
WIKA is more than just an instrument manufacturer. We offer a range of , from installations and repairs to safety testing, regardless of the instrument brand. As an ISO 9001 registered company, WIKA also has a Calibration & Service Center accredited by A2LA (American Association for Laboratory Accreditation).
Quality products, a worldwide network, and superb customer service are what make WIKA a leading supplier of measuring instrumentation for the chemical industry. Contact WIKA Canada for information on how to help your particular chemical processes run more safely and efficiently.
WIKA has worked with licensing and EPC companies for more than 30 years on major projects all over the world. We partner with you from the planning stages through to completion, and we provide post-project support. In addition to supplying high-quality process measurement instruments for temperature, pressure, level and flow applications, we can also work with you to develop solutions that meet your exact requirements.
WIKA also offers on-site expertise and technical support services to help ensure the success of your project. For more information, contact us.
The factors of capacity
Our high level of performance is essentially based on three factors: A wide and innovative product range, comprehensive and competent service and a reliable global presence. We are pleased to be committed to your success, too.
Engineering and Technical Services for Temperature, Pressure Measurement
As a true partner, WIKA is committed to helping you run as efficiently, reliably and safely as possible. We offer on-site engineering and technical services for your pressure and temperature measurement solutions to help you meet operational goals.
Whether you need us to troubleshoot an issue, calibrate an instrument, install or repair a multipoint assembly, or help develop a new specification or design, WIKA has experienced teams dedicated to providing the expertise and support you need.
Temperature Measurement Installation, Turnaround, Repair Services
WIKA Instruments Ltd field services include on-site engineering and supervision, turnaround, and installation and repair for::
- Tube Skin Thermocouple Assemblies
- Multipoint Assemblies
- Radial Temperature Measurement Systems
- Flexible Multipoint Assemblies
- Flame Rods, RTDs and Thermowells
Mechanical Pressure, Temperature Product Training, Audit, Turnaround Services
For mechanical pressure and temperature, WIKA developed the FAST program (Full Audit Service Team), which is a dedicated group of engineers who provide expertise to:
- Streamline your gauge population, and drive cost savings as well as maintenance and purchasing efficiencies
- Establish specifications for a new project or facility upgrade
- Troubleshoot recurring gauge failures
- Train your staff on best practices and establishing a sustainable gauge management process
FAST is a turnkey, value-added program, meaning you get engineering resources, including support with ERP and MOC documentation, for no more than you would spend for gauges.
The FAST services include: