Draft:Process analyzers
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Process analyzers
[edit]Process analyzers are on-line industrial instruments used to measure in real time chemical composition and/or physical properties of gases and liquids in process streams.[1] Process analyzers are normally used in process industries such as oil refining, petrochemicals production, power generation and chemical manufacturing to support process monitoring, control, safety functions, product quality assurance and optimization.[2]
Unlike laboratory analyzers, which measure discrete samples under controlled conditions, process analyzers are designed to operate within the industrial processes and provide measurements in real time or at frequent intervals.[3]
Overview
[edit]Process analyzers measure controlled variables (CVs) such as stream chemical composition and/or physical properties which enables to control and optimize process operation.[1] The measurement results are normally transmitted to distributed control systems (DCS) or supervisory control and data acquisition (SCADA) systems.[4]
In some applications, analyzer outputs are used for alarm functions or safety shutdown operations incorporated into safety-related systems.[5]
Measurement approaches
[edit]Process analyzers are commonly classified according to how they installed and how measurement is obtained from the process.[1]
Extractive analyzers
[edit]Extractive analyzers withdraw represenative sample from the process stream for on-line analysis.[1] The extracted sample is typically conditioned before measurement, which includes pressure reduction, filtration, water removal, cooling or heating.[6]
Extractive systems enables to use wide range of analytical techniques, including standard ASTM methods, but require sample systems, housing and extensive maintenance.[1]
In-situ analyzers
[edit]In-situ analyzers installed directly in the process and perform measurements within the stream without sample extraction.[7] This approach reduces response time and eliminates the need for additional sample conditioning systems.[1]
In-situ analyzers are used in applications involving high pressure, high temperature and specific applications where sample extraction is more difficult or can cause sample composition changes.[8]
Analyzer technologies
[edit]Process analyzers can be based on a variety of measurement techniques depending on the application and process conditions.[1] Common technologies include:
- Infrared and ultraviolet spectroscopy[9]
- Tunable diode laser absorption spectroscopy[10]
- Electrochemical sensors[11]
- Paramagnetic analysis[1]
- Thermal conductivity measurement[1]
- Gas chromatography[12]
- Near-infrared spectroscopy[13]
Each technique differs in selectivity, sensitivity, response time, suitability for specific operating conditions and correlation to the standard ASTM methods.[1]
Applications
[edit]Process analyzers are used in a range of industrial applications, including:
- Chemical composition and physical properties monitoring in refining and petrochemical processes
- Detection of impurities in gas and liquid streams
- Quality control in chemical and pharmaceutical manufacturing
- Combustion control and emissions monitoring
- Detection of abnormal or unsafe process conditions
Continuous measurement enables earlier detection of process deviations compared with periodic laboratory analysis and provides facility for advanced process control (APC) and real-time optimization (RTO).[3]
Integration with control systems
[edit]Analyzer outputs are typically integrated into DCS or SCADA automation systems.[4] Measurement results can be used as control inputs, displayed to operators, or combined with other process data.
In some installations, analyzer signals are used in protective or interlock safety functions, subject to applicable safety and hazardous-area standards.[5]
Maintenance and reliability
[edit]Process analyzers operate continuously in industrial environments and require established maintenance procedures to ensure measurement accuracy and reliability.[1] These procedures include calibration, verification against reference standards, validation and predictive maintenence.[14]
In extractive systems, sampling components such as filters, valves and regulators shall be regularly inspected and repaired or replaced to provide the required measurement quality.[15] In in-situ systems, performance may be influenced by process conditions such as temperature, pressure and exposure to corrosive components, which requires special attention to material compatability and pressure/temperature limitations.[16]
References
[edit]- 1 2 3 4 5 6 7 8 9 10 11 Perry, R.H.; Green, D.W. (2019). Perry’s Chemical Engineers’ Handbook (9th ed.). McGraw-Hill.
- ↑ "Industrial Measurement and Control". National Institute of Standards and Technology.
- 1 2 "Process Analytical Technology (PAT)". U.S. Food and Drug Administration.
- 1 2 "Process Control and Instrumentation". IEEE Control Systems Magazine. 2018.
- 1 2 "IEC 61508 Functional Safety". International Electrotechnical Commission.
- ↑ Sample Conditioning for Process Analyzers. Elsevier. 2012.
- ↑ Process Measurement and Analysis. ISA. 2015.
- ↑ Industrial Process Measurement and Control. Butterworth-Heinemann. 2014.
- ↑ Spectroscopic Methods in Process Analysis. Springer. 2010.
- ↑ "Tunable diode laser spectroscopy for industrial gas analysis". Applied Physics B. 2003.
- ↑ Electrochemical Sensors in Industrial Applications. Wiley. 2008.
- ↑ Gas Chromatography: Principles and Applications. Wiley. 2013.
- ↑ Near-Infrared Spectroscopy in Process Analysis. CRC Press. 2007.
- ↑ Maintenance of Process Instrumentation. ISA. 2016.
- ↑ Process Sampling Systems. Elsevier. 2011.
- ↑ Industrial Instrumentation and Control Systems. McGraw-Hill. 2015.
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