Diaphragm Pump:

These types of pumps are used to transfer the fluids with high, low, or medium viscosities & also fluids
with huge solids content.

A diaphragm pump is a PD or positive displacement pump. It is also called as a membrane pump. This
pump works with using a blend of the reciprocating action of a rubber, Teflon diaphragm otherwise
thermoplastic & appropriate valves on any face of the diaphragm to push a liquid.

Diaphragm Pump Characteristics

1. The flow of liquid is with pulsation

2. When the fluid enters the tube with the functioning of a check valve, then it constantly supplies
out from the higher side.
3. The check valve closing is complicated.

The diaphragm pump advantages include the following.

1. These pumps are not expensive due to the proper maintenance

2. Self-priming
3. Explosion proof
4. Changeable flow rate and expulsion pressure
5. Portable
6. Easy installation
7. They can operate in the long term
8. These are energy-efficient as they apply extra force while the forward hit of the pump.
9. These are well suited for pumping chemicals otherwise other harming fluids
10. These pumps are suitable to conquer standing force within the flow line.

TURBINE METERS
In turbine meters, a digital output is generated, which is linear with the process flow, as the speed of
rotation of the turbine is measured. Turbine meters can be used in both liquids and gases, and they are
suitable for the measurement of both very low and very high flow rates, as insertion designs. The liquid
turbine meter is one of the most accurate meters available for low- to medium-viscosity products. Range
ability of single turbine meters is around 10:1, for dual-turbine meters, it exceeds 100:1. Turbine meters
can be used under practically any pressure and for applications involving extremely high and low
temperatures. They are easy to install and, relative to the pipe diameter, are also small in size and
weight. The meter provides a very fast response speed and is suitable for hygienic applications.

Their principal limitations include high cost, incompatibility with viscous or dirty liquids, and the
potential for being damaged by over-speeding if slugs of gas or vapor are sent through the liquid meter.
The installation of upstream filters is often recommended, in spite of the fact that it increases both the
pressure drop and the maintenance requirement of the installation. Turbine meters are widely used
when high-accuracy measurements are required in applications involving product sales. They are also
used when high accuracy is required in blending, on test rig (Ratio in guarantee) duty, and in general
measurement. Variations on the basic turbine flowmeter design include
  Nonelectric (fiber optic) detectors;
 Turbine probes;
 Bearing less “hover-flow” designs; and
 Various paddlewheel,
 Impeller, and
 Shunt-flow designs.

The impeller and paddle-flow designs cost less but also provide less accuracy than traditional turbine
flowmeters.

Elbow Taps
Elbow taps measure the flow rate by detecting the differential pressure between taps located on the
inner and outer radii of an elbow. In larger pipes, this results in a very low-cost installation, because pipe
size does not affect cost. This is a crude, inaccurate measurement, requiring high flow velocities and long
upstream, straight pipe lengths.

Open Drain Tundish:

A tundish is a fitting installed on pipes to provide an air-gap and catch any drips caused by overflow. This
in turn helps prevent unsanitary cross connection, water damage or spillage.

Breather Valve/ Air Pressure Relief Valve:

A breather is an essential component of a gearbox. If a breather is not installed, pressure can build up
and cause oil to leak by one or more seals from the gearbox. A typical breather prevents this pressure
from building by allowing hot air to escape and fresh, cooler air to come in.

Chemical Seal/ Diaphragm Seal:

A diaphragm or chemical seal is a device comprised of a thin membrane known as a diaphragm, which is
clamped between two flanges. This unit is gasketed to prevent fluid leakage. A diaphragm seal acts as a
barrier between the process fluid and the pressure sensing element.

Diverter valve
Diverter valves direct bulk solids into different destinations as part of a dilute or dense phase pneumatic
conveying system. Typically, they help convey material from one source to two destinations (or reverse)

What is the purpose of a flapper valve?

A flapper valve is a type of valve used in flush toilets. It creates the watertight seal in the toilet tank that
holds the water until flushing. When one pushes the handle, the flapper rises, allowing the water to
flush out the excreted items, the flapper then goes back down and recreates the watertight seal.

Sub Surface Safety Valve:

Safety valves are designed to automatically shut in the flow of a well in the event surface controls fail or
surface equipment becomes damaged. They are classified according to the location from which they are
controlled – surface or subsurface. In this article, subsurface safety valve types, operating systems,
working principle, setting depth, and selection process are presented.

It is advisable, and in most cases mandatory, to have a secondary means of closure for all wells capable
of natural flow to the surface. The installation on of a sub-surface safety valve (SSSV) will provide this
emergency closure capability.
A safety device installed in the upper wellbore to provide emergency closure of the producing conduits
in the event of an emergency. Two types of subsurface safety valve are available: surface-controlled and
subsurface controlled. In each case, the safety-valve system is designed to be fail-safe, so that the
wellbore is isolated in the event of any system failure or damage to the surface production-control
facilities.

Corrosion Coupon:
Corrosion coupons are pre-weighed and measured metal strips which are mounted in a special pipe
system called a coupon rack. They are used to estimate the rate of metal corrosion by comparing the
initial weight with the weight following 60, 90 or 120 days of exposure to the water in the system.

Corrosion Probe:
Corrosion Probes are electrical resistance corrosion monitoring devices used in many industries to
monitor real-time corrosion rate without removing corrosion probe.

Electrical resistance (ER) corrosion probes are commonly used in petroleum, chemical processing, and
other environments where on-line corrosion rate readings are required.

Flow Computer:
A flow computer is an electronic computer which implements algorithms using the analog and digital
signals received from flow meters, temperature, pressure and density transmitters to which it is
connected into volumes at base conditions.

Sight glass
A sight glass or water gauge is a type of level sensor, a transparent tube through which the operator of a
tank or boiler can observe the level of liquid contained within.

Demister pad
A demister pad, is a device used for removing entrained liquid droplets from a gas stream. As the name
suggests the demister is used for removal of the mist from gaseous phase. Demisters are often fitted
just below the top vapor outlet of a vapor liquid separator

Demister pad, also called mist eliminator, vapor pad, is made of knitted wire mesh, which is woven
interlocked and ensure the even and smooth meshes for filtering. ... Material: galvanized wire, copper
wire, monel wire, nickel wire, stainless steel wire, plastic wire.

Reciprocating compressor
A reciprocating compressor or piston compressor is a positive-displacement compressor that uses
pistons driven by a crankshaft to deliver gases at high pressure.

The intake gas enters the suction manifold, then flows into the compression cylinder where it gets
compressed by a piston driven in a reciprocating motion via a crankshaft, and is then discharged.
Applications include oil refineries, gas pipelines, chemical plants, natural gas processing plants, air
conditioning and refrigeration plants.

Motor control center (MCC)

A motor control center is an assembly to control some or all electric motors in a central location. It
consists of multiple enclosed sections having a common power bus and with each section containing a
combination starter, which in turn consists of motor starter, fuses or circuit breaker, and power
disconnect.

Introduction  A motor control center (MCC Panel) is an assembly of one or more enclosed sections
having a common power bus and principally containing motor control units.  Motor control centers are
in modern practice a factory assembly of several motor starters.

Thermo Well
Thermo wells are cylindrical fittings used to protect temperature sensors installed in industrial
processes. A thermo well consists of a tube closed at one end and mounted in the process stream.

Temperature Element
There are several temperature element instrument types widely used to measure temperature of a
process substance. These types are categorized into mechanical temperature element and electronic
temperature element. Mechanical temperature element uses the principle of thermal expansion i.e. the
element expands if the temperature rise and vice versa. Electronic temperature element use the
principle of electrical properties change following of temperature variation.

Mechanical Based Temperature Element

Solid element: Bimetallic is temperature element instrument formed from two types of metal which
have different thermal expansion properties. These two metal are bonded together become one strips.
The metal strips will bend if temperature changes. At free end of bimetal, the pointer is attached to
indicate the result of temperature measurement.

Gas element: Gas filled system is temperature element instrument based on principle of the ideal gas
law. It consist of bulb/stem, capillary and bourdon tube. The sensing element is a rigid bulb or stem
containing a gas. If the temperature rises, the volume remain constant since the bulb is rigid, while the
gas pressure increase proportionally. The change in gas pressure is measured by a pressure element
such as bourdon tube.

The bulb and the bourdon tube is connected by a capillary tube allowing the temperature indicator to be
located not directly attached to the piping/vessel being measured. This advantages allows the
temperature gauge indicator being mounted on the convenient location whereas the tapping point of
process fluid to be measured is not permanently inaccessible.

However the capillary might loss heat therefore the addition of compensation is required to eliminate
the error. www.instrumentationportal.com

Liquid element: Liquid temperature element utilizes mercury constrained within a bulb/stem. Mercury
is no longer preferred in most process application although it provides fast response and good accuracy.
Mercury mostly used in glass stem thermometer for non-process industry such as body temperature
measurement.

Electronic based Temperature Instrument

The most two commonly used electronic temperature element are Resistance Temperature Detector
(RTD) and Thermocouple. To indicate the temperature measurement, these elements need to be
connected to control system by wired directly or using temperature transmitter.
Resistance Temperature Detector: Resistance Temperature Detector (RTD) works based on principle
that resistance of a metal varies with its temperature. RTD is the most commonly used type in process
measurement due to its good stability, accuracy, repeatability.

Thermocouple: Thermocouple consist of two dissimilar metals of which the junction generates a voltage
proportional to the junction temperature. The Thermocouple is selected for service which requires wide
range (very high – low temperature). The other advantages of thermocouple over RTD are it has more
rugged design and also provide faster response.

Hooter
The fire alarm Hooter and Sounder are Audio indications to fire Signals. Alarm Hooter plays a crucial role
of vital importance by creating a Hooter Like Sound as and when the control monitoring Panel Detects a
fire signal from any zone. Fire Detection Equipment or Module.

Fire Extinguisher
A fire extinguisher is an active fire protection device used to extinguish or control small fires, often in
emergency situations. It is not intended for use on an out-of-control fire, such as one which has reached
the ceiling, endangers the user, or otherwise requires the expertise of a fire brigade.

Recycle Valve
Compressor recycle valves are used to recycle gas flow from the compressor discharge to the suction
and prevent operation below the surge point. The valve protects the compressor from the destructive
effects of low-capacity operation when the surges of flow reversal can actually destroy the compressor

Swing Valve:
A swing check valve is mounted with a disc that swings on a hinge or shaft. The disc swings off the seat
to allow forward flow and when the flow is stopped, the disc swings back onto the seat to block reverse
flow. Swing check valves are often installed where personnel is present.

Venturi valve
Triatek's Venturi Valves maintain a desired airflow regardless of duct pressure. ... As the duct pressure
increases, the spring compresses and pushes the cone further into the shell. This mechanism keeps the
volumetric flow rate constant as air travels through the valve and duct pressure varies.

Knife gate valve

Knife gate valves are designed mainly for on-off and isolation services in systems with high content of
suspended solids. Knife gate valves are designed to work in some of the most harsh environments,
typically having a sharpened blade to cut through heavy liquids.

Ball check valve

A ball check valve is a check valve in which the closing member, the movable part to block the flow, is a
ball. In some ball check valves, the ball is spring-loaded to help keep it shut. Ball check valves are often
very small, simple, and cheap.
Lift Check Valve
A lift-check valve is a check valve in which the disc, sometimes called a lift, can be lifted up off its seat by
higher pressure of inlet or upstream fluid to allow flow to the outlet or downstream side. A guide keeps
motion of the disc on a vertical line, so the valve can later reseat properly.

Piston Check Valve

Piston and ball check valves, like all check valves, are used to pre- vent back flow in the line. ... PISTON
CHECK VALVE The pressure of the fluid passing through a system opens the valve, while any reversal of
flow will close the valve. In Piston, or lift, check valves a body-guided disc moves within the body bore.

Tilting Disc Check Valve:

A tilting disc check valve is a check valve where the disc has a pivot point at the center of the disc. It is
also known as a tilt check valve or a tilting-disk check valve. The valves are used when there is frequent
flow reversal.

Wafer check valve

Wafer check valves have a solid thermoplastic body with a very thin "wafer" profile that makes them an
ideal check valve for applications that require valves with short takeout lengths. Wafer check valves are
used in applications where it is essential to ensure fluid flow passes in only one direction.

Expanded Wedge Valve:

The expanding gate valve can be trimmed to meet most specifications that require handling a wide
range of products and services. The extensions and adaptation for actuation are options regularly
requested and provided. When the valve is completely closed, the gate and segment are wedged tightly
against each seat. During operation, the gate and segment retract from the seats before travel. This
retraction reduces wear on the resilient seat material and protects sealing surfaces in the open and
closed positions.

Features/Benefits

Provable zero leakage

Double block-and-bleed

Reduced wear on sealing surfaces

Repeated positive shutoff

Inline repairable

External thermal body relief

Press-fit seats

Injectable stem packing

Manufactured and tested to API 6D and ANSIB16.34 specifications

Process Upset
A sudden, gradual, or unintended change in the operational behavior of a process. It may be due to
process equipment failure or malfunction, operator intervention, a surge or fall in pressure, flow, level,
concentration, etc.

Orifice plate:

Restriction Orifice:

Fugitive emissions
Fugitive emissions are emissions of gases or vapors from pressurized equipment due to leaks and other
unintended or irregular releases of gases, mostly from industrial activities. As well as the economic cost
of lost commodities, fugitive emissions contribute to air pollution.

Liquid Carry Over

A phenomenon in which free liquid leaves with the gas phase at the top of a separator. Carryover can
indicate high liquid level, damage of the separator or plugged liquid valves at the bottom of the
separator.

Effects:

– High inlet flow-rate to the oil gas separator which is caused by bad manifold distribution, this will lead
to high flow-rate to some separators and low flow-rate to others.
– Closing oil outlet valve mistakenly, or a technical problem in it.
– Oil level indicator false signal, which will lead to raise the oil level in the separator.
– a technical problem in pressure control valve, this will decrease the separator pressure causing oil
level to increase and pass the mist extractor, then escape with gas.

How to solve Carry Over?

– If there is a bad manifold distribution, we have to re-organize the flow-rate to each oil gas separator,
this will guarantee not to overload any separator with excessive flow.

– If there is idle manual valve in any separator, then we have to shut down it, then fix or replace this
valve.

– Calibrate the control valves. Then check level and pressure indicators.

Gas blowby
Gas blowby is opposite of the Carry-over. It occurs when free gas escapes with the liquid phase and can
be an indication of low liquid level, vortexing, or level control failure.

How to solve BlowBy?

If there is any malfunction in the control valve; they need to be fixed then re-calibrated.

Then we have to have a look at pressure and level indicators, to be sure that they are accurate, but in all
cases we have to vent the pipeline from any vent point.

Water Seal
Seals installed in the stack prevent flashback of the flame, and a vessel at the base of the stack removes
and conserves any liquids from the gas passing to the flare.

To recover flared gas, after collecting from flare header, it is diverted to the FGRS downstream of the
knock-out drum by a liquid seal vessel and passes through a compressor.

In the event that the flow capacity of the FGRS is exceeded, the liquid seal vessel will allow the excess
waste gas to go to the flare where it is safely burned

Flare stack
In industrial plants, flare stacks are primarily used for burning off flammable gas released by safety
valves during unplanned over-pressuring of plant equipment. During plant or partial plant startups and
shutdowns, they are also often used for the planned combustion of gases over relatively short periods.

Flare Pits
Flare pits were once commonly used to store and burn disposed petroleum hydrocarbons (PHCs) and
other oilfield waste.

Earthen pits are constructed below the flare stacks to contain any fluids present in the gas stream.
Typically, flare stacks collect precipitation which mixes with residual oils and other liquids and create
small ponds

Sump pumps/ Pit

Sump pumps work by gathering any excess water in your home into a ditch (also known as a sump pit)
that has been installed in your basement floor. Once the water hits a predetermined level, the sump
pump will automatically dispose of the water by transferring it out of your home into a local sewer
drain.

Flame Impingement
Flame impingement is when a flame actually touches or engulfs the tubes or their supports. This
condition is one of the major problems encountered in hard-firing heaters, and it can occur due to
inadequate design, poor operation or poor maintenance.

When flame impingement occurs for even a short duration, damage is done. Consequences can include
failures in tubes that carry process fluids, tube supports, refractory, burners, casing and structural
integrity.

See more
Fired heaters are used considerably in the chemical process industries (CPI), for heating crude oil in the
petroleum refining and petrochemical sectors. Unfortunately, fired heaters are often taken for granted
and neglected more than other equipment in terms of operation and maintenance. Proper care and
attention to these heaters can prolong run lengths and increase reliability and safe operation. A
common reaction to the need for more heat duty is to pump more fuel into the burners of a fired
heater, without cross checking its heat-release design limits. This can cause long-term problems like
flame impingement, tube bowing, sagging, leakage, rupture, damage and even explosion.

Purge Gas
In fire and explosion prevention engineering, purging refers to the introduction of an inert purge gas
into a closed system to prevent the formation of an ignitable atmosphere. Purging relies on the principle
that a combustible gas is able to undergo combustion only if mixed with air in the right proportions.

See More
1. Liquid seal drums are vessels that are used to separate the relief gases and the flare/header
stack by a layer of liquid. Water (or water/glycol mixture) is normally the sealing fluid. The flare
gas (or purge gas) is forced to bubble through a layer of water before it reaches the flare stack.
2. Purge gas is injected into the relief header at the upstream end and at the major branches to
maintain a hydrocarbon-rich atmosphere in each branch, into the off-plot relief system, and into
the flare stack. The gas volume typically is enough to maintain the following velocities: ft/s for
density seals, 0.4 ft/s for fluidic seals, and 0.4 to 3 ft/s for open-ended flares. RP 521 states that
the oxygen concentration must not be greater than 6% at 25 ft inside the tip. When there is
enough PSV leakage or process venting to maintain the desired backpressure, no purge gas is
injected.
3. Purging is the act of removing the contents of a pipe or container and replacing it with another
gas or liquid. Purging is crucial in pipeline, piping, welding and industrial process. It removes
contaminants from the piping and vessels, which reduces chances of corrosion.

Volatile Substance
A substance is said to be volatile if it boils at a low temperature, changing from the liquid to the gas
phase. Substances that are gases at room temperature are extremely volatile: they have high volatility.
They can only be seen as liquids when exposed to low temperatures or high pressures.

Gas Chromatography:
Gas chromatography (GC) is an analytical technique used to separate the chemical components of a
sample mixture and then detect them to determine their presence or absence and/or how much is
present. These chemical components are usually organic molecules or gases

Piezoresistive or Piezoelectric or Inductive Sensor

https://www.americanpiezo.com/knowledge-center/piezo-theory/piezoelectricity.html

Specific Gravity

Specific Gravity = (Density of Object) / (Density of Pure water at 4 deg. Celsius) [Unit % ]

For Gaseous object it’s sometime the Air Density.

Linear Valve: If a valve should be called linear only if its gain (Gv) equals the maximum flow through the
valve (Fmax) divided by the valve stroke in percentage (100%).