T H E R M A T E L® T H E R M A L D I S P E R S I O N M The Total Spectrum of Solutions Magnetrol’s products employ many technologies to meet the challenges of level and flow control. Thermatel switches and transmitters utilize the principles of thermal dispersion for accurate and reliable level, flow, and interface control. MAGNETROL THERMAL DISPERSION PRODUCTS M agnetrol International —a world leader in level and flow control technology— designs, manufactures, markets and services level and flow instrumentation worldwide. Magnetrol’s product groups are based upon these technologies: • Air Sonar • Buoyancy • Contact Ultrasound • Guided Wave Radar • Pulse Burst Radar • RF Capacitance • Thermal Dispersion • Vibration • Visual Indicators The industries we serve include: • Petroleum Production • Petroleum Refining • Power • Petrochemical • Chemical • Water & Wastewater • Pulp & Paper C O N T E N T S Thermal Dispersion Technology • An Introduction to Thermatel 4 Thermatel Thermal Dispersion Products: • TA1 & TA2 Mass Flow Transmitters • TD1 & TD2 Flow/Level/Interface Switches • TG1 Level/Flow/Interface Switch • Thermatel Sensors • Thermatel 052-7201 Switch • Thermatel RPA Hot Tap Assembly 6 8 9 10 11 11 • Food & Beverage • Pharmaceutical 3 An Introduction To Thermatel Technology & Products T hermatel products utilize thermal dispersion technology for unsurpassed accuracy and reliability in monitoring gas flow, liquid flow, liquid level, and interface. A market-proven technology, thermal dispersion has been in use by process industries for measurement and control purposes since the early 1960s. Product Scope The Thermatel product line has been structured to provide customers with a complete range of options in thermal dispersion technology. Each Thermatel product is engineered and manufactured to provide the highest reliability in even the most demanding process environments. Thermatel products range from single-point switches to the powerful TA1/TA2 Thermal Mass Flow Transmitters. The TA1/TA2 powerful microprocessor-based electronics make these units the premier thermal dispersion mass flow meters in the industry. They are easy to set up, configure, and provide high levels of accuracy, repeatability, and diagnostics. High Temperature Differential © ©© © © © © © Low Temperature Differential Thermatel switches employ twin RTD sensors to sense process change in level and flow applications. One sensor measures the surrounding process temperature to provide a reference. The second sensor is self-heated to establish a temperature differential above the reference temperature. In level applications, the cooling effect of contacting media reduces the temperature difference between the RTDs. In flow applications, an increase in flow rate further decreases the temperature difference. In each instance, the decrease in temperature difference triggers a relay action. 4 Applications Range Thermatel products are in service worldwide in many of the most demanding applications. As a flow switch Thermatel is used for gas and liquid applications for both flow and no/low flow detection. Typical applications involve pump protection, cooling air/water, relief valve monitoring, exhaust flows and lubrication systems. Thermatel products provide outstanding low flow sensitivity with high rangeability. Insertion probe designs for Thermatel switches use two basic RTD configurations. The twin-tip design with exposed sensor tips is available in a broader range of materials and sustains higher pressures. The spherical tip design (only available in 316L stainless steel) offers greater sensor protection and a faster response to reduction flow or level. Thermatel level switches provide outstanding performance with liquids and slurries in a wide variety of demanding applications including interface, high viscosity, turbulence, high temperatures, and presence of foam. For mass flow measurement of air and gases, the Thermatel TA series Thermal Mass Flow Transmitters are without peer. The easy to use instrument is installed in numerous flow measurement applications including combustion air flow, compressed air/gas and aeration air flow measurement. Other common applications include natural gas, digester/bio gas, flare lines, hydrogen, oxygen, and many other gas flow measurement applications. Principle of Operation: Switches Flow and level detection is accomplished when Thermatel’s sensing elements detect changes in the heat transfer characteristics of the process media. As a flow switch, Thermatel switches will rapidly detect changes in liquid or gas flow rate by detecting heat transfer, which increases at higher flow rates. Level detection is accomplished by sensing changes in the thermal conductivity of media. Thermatel switches can also be calibrated to sense difference in heat transfer at an interface between two dissimilar media, such as oil/water, or water/foam. Reference RTD Active RTD Mass balancing element Heater Power Transmitter Mass Flow Thermatel switches rely on two miniature sensing elements to detect heat transfer. Resistance Temperature Detectors (RTDs) establish a thermal relationship that establishes the basis for flow and level detection. One RTD measures the temperature of the surrounding media which serves as the instrument’s reference temperature. The second RTD is heated to establish a temperature differential above the reference temperature. In flow sensing applications, the heated RTD cools with increasing flow. In level sensing applications, the RTD cools in the presence of media. In each case, cooling the heated RTD decreases the differential temperature between the two RTDs. This decrease is then converted into a relay actuation which performs an alarm function. Principle of Operation: Flow Meter Thermal dispersion technology provides a mass flow measurement of air or gas. This is accomplished by precisely measuring the cooling effect as the mass (molecular) flow passes the heated sensor. The sensor consists of two elements: the reference which measures the temperature of the gas and a second element which is heated at a variable power. This maintains the desired temperature difference between the two sensors. Each instrument is factory calibrated and configured for the specific application. If necessary, the TA1 or TA2 can be reconfigured in the field for different conditions. Strengths and Cautions Direct mass flow measurement—does not require pressure or temperature compensation which is required by other technologies. Thermatel offers excellent low flow sensitivity: gas velocities from 25 ft/min (0.13 m/s) to over 40,000 ft/min (200 m/s). Thermatel products are easy to install and can be “hot tapped.” An alternative flow meter technology should be considered where condensed moisture is continuously present. Refer to Magnetrol bulletin 54-621 for further technical information on Thermal Dispersion Mass Flow. The illustration on the top of this page shows the amount of power required to maintain a constant temperature difference between the two sensors. Under low mass flow conditions, there is minimal cooling and little power is required. As the mass flow increases, more power is required. This provides excellent low flow sensitivity and high turndown capabilities. 5 THERMATEL TA1 & TA2 Mass Flow Transmitters Mass Flow Measurement of Air and Gas General Description: Magnetrol’s TA1 and TA2 Thermal Dispersion Mass Flow Transmitters provide direct mass flow measurement of air and gases. The powerful microprocessor-based electronics provide an instrument that is easy to configure to the application, yet provides flexibility and ease of use. Advanced temperature compensation provides high accuracy over the entire operating range of the instrument. Installed cost of this instrument is very competitive with other gas mass flow measurement technologies. L L L L L Technology Features: Direct mass flow measurement in SCFM, Nm3/h, lb/hr, kg/hr Excellent low flow sensitivity High turndown ratios Ease of installation Low pressure drop L L L Product Features: Flow totalizer 2 line × 16 character display of flow, temperature, and totalized flow Stainless steel and Hastelloy® probe with wide selection of process connections Model TA2 Mass Flow Transmitter L L L NIST traceable calibration. Optional Hot Tap Retractable Probe assembly Temperature compensation Applications: Typical applications include combustion air-flow measurement, compressed air, natural gas flow, flare lines, digester/bio gas, and other process gas flow measurement. Model TA1 Mass Flow Transmitter In Magnetrol’s Product Calibration Lab, Thermatel products are calibrated and tested to meet customer specifications. Calibrations traceable to NIST. Model TA2 with Flow Body 6 THERMATEL TA1 L L L L L L L Unique Features: Remote electronics (2) 4–20 mA signals—one for mass flow and one for temperature Up to four 10 amp relays (optional) 16 button keypad integral to front cover NEMA 4X housing plus Class I, Division 2 Non-Incendive rating RS-485/Modbus® communications Explosion proof probe enclosure THERMATEL TA2 L L L L L L Unique Features: Integral or remote electronics HART®, AMS communication All explosion proof housing with FM/CSA and ATEX hazardous area approvals Ability to replace probe in field 4-button keypad for data entry Response time 1 to 2 second time constant APPROVALS S P E C I F I C AT I O N S Supply Voltage 120 VAC, 50–60 Hz, +10%/-15% 240 VAC, 50–60 Hz, +10%/-15% 24 VDC ±20% Power Consumption 6 watts, 9 VA Flow Range Maximum 25–40,000 SFPM (0.13–200 Nm/s) air reference to standard conditions Higher ranges and other gases available Accuracy Flow ±1% of reading +0.5% of calibrated full scale Accuracy Temperature ±2° F (1° C) Repeatability ±0.5% of reading Turn Down 100:1 typical (depending on calibrated flow range) Ambient Temperature -40° to +160° F (-40° to +70° C); display not readable below -4° F (-20° C) Process Temperature -50° to +400° F (-45° to +200° C) Pressure Rating 1500 psig (103 bar) maximum Analog Output Signal Active: 4–20 mA (isolated) maximum 1000 Ω loop resistance Passive: 4–20 mA (isolated) loop resistance dependent on power supply HART Optional 7 THERMATEL TD1 & TD2 Switches Flow / Level / Interface Detection General Description: The TD1/TD2 Thermatel switch is extremely versatile providing flow/level/interface detection in a single unit. Both liquid and gas flow detection is obtainable. The TD1 is available with 24 VDC power with the TD2 available in either an AC or DC version. The TD2 also provides LED indication through an optional glass window, mA output for diagnostics or repeatable flow/level indication, optional hermetically sealed relay, time delay adjustment, and remote electronics. Continuous diagnostics on both units provides assurance that the switch is operating properly. L L L L L L L L L L L L Features: Continuous diagnostics Temperature compensation No moving parts Narrow hysteresis Operating temperatures to +850° F (+450° C) Integral or remote electronics 8 amp DPDT relay with optional hermetically sealed relay Low flow sensing capabilities Probes available in 316 stainless steel, Hastelloy® C, and Monel® Wide selection of sensors – see page 10 NACE construction available Optional sanitary probe Applications: Flow: Pump protection, relief valve monitoring, low flow/high flow indication, cooling air/water, exhaust flow, analyzer lines, lubrication systems Level: High level/low level/interface detection, high viscosity liquids, slurries, high pressure, high temperature, air/foam and foam/liquid detection, corrosive environments APPROVALS S P E C I F I C AT I O N S Input Power TD1: 19.2 to 28.8 VDC TD2: 100 to 264 VAC, 50–60 Hz or 19.2 to 28.8 VDC Power Consumption TD1: 3.5 watts at 24 VDC, 4.5 watts at 30 VDC TD2: 4 watts at 24 VDC, 4.5 watts at 30 VDC, 5 watts at 100 to 264 VAC Power to Probe Electronics Less than 1 watt TD1: Integral TD2: Integral or remote Relay Set Point Range 8 amp DPDT — TD2 has optional hermetically sealed relay Water: 0.01 to 5 fps (0.003 to 1.5 m/s) Air: 0.1 to 500 sfps (0.3 to 150 nm/s) 8 Process Temperature -100° to +850° F (-73° to +454° C) Process Pressure Probe dependent — to 6000 psig (414 bar) THERMATEL TG1 Switch Two-Wire Intrinsically Safe Flow / Level / Interface Detection General Description: Magnetrol’s TG1/TG2 switch is the industry’s only two-wire, intrinsically-safe thermal dispersion switch. The switch consists of a probe and preamplifier with remote DIN rail electronics. Barriers in the DIN rail enclosure provide a two-wire, intrinsically-safe circuit to the probe/preamplifier. Product Operation: The preamplifier converts the temperature difference to a pulse signal which is super-imposed on the two wires providing power to the sensor. The DIN rail electronics provide operation control including set point adjustment, LED indication of flow/level, relay, fail-safe adjustment, and time delay. A non-linear mA output signal is available for diagnostics and repeatable flow/level indication. L Features: DIN rail mounted electronics with built-in barrier provide a two-wire intrinsically-safe circuit to the probe/preamplifier L L L L L Versatile switch for flow and level Set point adjustment at remote electronics Up to 1,650 feet (500 meters) cable length LED indication provides monitoring of actual flow/level mA output signal will provide repeatable indication plus can be used for diagnostics L Uses all Thermatel probes including low flow body and high-temperature sensor Applications: Flow: Liquid or gas flow, pump protection, cooling air/water, relief valves, flow/no flow Level: Hi/Low level, high viscosity media, high solids content, aeration/foaming, sanitary applications, interface detection, hightemperature applications APPROVALS S P E C I F I C AT I O N S Supply Voltage 24 VDC Relay 2 amp, SPDT relay Signal mA output, non-linear Fail-safe Switch selectable LED Indication 4 Green: Flow/Level is normal 1 Yellow: Flow/Level is near set point Operating Temperature Sensor: -100° to +850° F (-70° to +450° C) Flow Range Insertion Probes Water: 0.01 – 5 fps (0.003 to 1.5 m/s) Air: 0.1 – 500 fps (150 m/s) 1 Red: Alarm condition (TG1 only) Set-Point Adjustable via potentiometer 9 THERMATEL Switch Sensors Twin-Tip Sensors are mounted at the end of each tip. Spherical Sensors are bonded directly to the wall of the tip for greater sensitivity and sensor protection. Probe pressure and temperature ratings are dependent upon process connection; maximum pressure and temperature ratings are shown below. Twin-Tip Sensor General Use: General purpose and corrosive resistant applications Material Options: 316 stainless steel, Hastelloy C-276, or Monel Process Connections: NPT threads, G threads, ANSI flanges, EN/DIN flanges Max Temperature: +400° F (+200° C) Max Pressure: 3,000 psig (207 bar) – 1850 psi (127 bar) extended length Insertion Lengths: 2 to 130 inches (50 to 3,300 mm) Spherical-Tip Sensor General Use: General purpose service and high-viscosity applications Material: 316 stainless steel Process Connections: NPT threads, G threads, ANSI flanges, EN/DIN flanges, Sanitary Max Temperature: +400° F (+200° C) Max Pressure: 600 psi (40 bar) Insertion Lengths: 2 to 130 inches (50 to 3,300 mm) High-Temperature Sensor General Use: For high-temperature process environments Material: 316 stainless steel; Hastelloy C-276 Process Connections: NPT threads, G threads, ANSI flanges, EN/DIN flanges Max Temperature: +850° F (+454° C) Max Pressure: 6,000 psi (413 bar) Insertion Lengths: 2 to 36 inches (50 to 900 mm) Low Flow Body Sensor General Use: Low flow detection; suitable for chemical feed pumps, additive flow, pump seals, process analyzers Material: 316 stainless steel Flow Rate: 0.055 to 3 gallons/hour (0.02 to 11.5 liters/hr.) Process Connections: 1 Max Temperature: +400° F (+200° C) Max Pressure: 5,800 psi (400 bar) ⁄4" and 1⁄2" NPT, and G threads Mini Sensor 10 General Use: Probes specifically designed to fit into a 1⁄2", 3⁄4", or 1" Tee Material: 316 stainless steel Max Temperature: +400° F (+200° C) Max Pressure: 3000 psi (1850 bar) extended lengths Insertion Length: 1 to 130 inches (25 to 3300 mm) THERMATEL 052-7201 Switch Flow Switch for Naval Applications General Description: The Thermatel “Navy Switch” is a special version of the Thermatel switch. It is used by the United States Navy for use on board Naval ships for flow detection in sprinkler systems. Features: L Meets MIL-S-901D: Grade A shock requirements L Meets MIL-STD-167-1: Vibration requirements L Unit comes with Tee for use with MIL-T-16420 CUNI tubing (For tubing sizes: 1.25", 1.50", 2.00", 2.50", 3.00" or 4.00") L 120 VAC power L 10 amp DPDT relay L Calibrated for sprinkler systems to detect flow of 10 GPM with 10-second delay time THERMATEL RPA Hot Tap Assembly Allows probe installation or removal without process shut-down General Description: When used with Thermatel insertion probes, the Retractable Probe Assembly (RPA) permits the probe to be installed or removed from the vessel or pipe while the process remains in operation. Once installed, it is not necessary to drain or depressurize a tank or shut down the operation in order to install or remove a Thermatel instrument. Features: L Standard 316 stainless steel gland construction L Carbon steel or stainless steel process connections L Flange and ball valve available as an option L 11⁄2" NPT or flange connection L Teflon® compression rings Capabilities: L Temperatures to +400° F (+200° C) L Standard pressure to 50 psi (3.4 bar) (80 psi (5.5 bar) for TA1/TA2) L High-pressure design option to Class 300 pound service Thermatel Hot Tap Assemblies: Standard Design (Left) and High Pressure Design (Right). 11 CORPORATE HEADQUARTERS 5300 Belmont Road • Downers Grove, Illinois 60515-4499 USA Phone: 630-969-4000 • Fax: 630-969-9489 www.magnetrol.com • [email protected] EUROPEAN HEADQUARTERS Heikensstraat 6 • 9240 Zele, Belgium Phone: 052 45.11.11 • Fax: 052 45.09.93 BRAZIL: Av. Dr. Mauro Lindemberg Monteiro • 185-Jd. Santa Fé, Osasco • São Paulo CEP 06278-010 CANADA: 145 Jardin Drive, Units 1 & 2 • Concord, Ontario L4K 1X7 CHINA: Room #8008 • Overseas Chinese Mansion • 129 Yan An Road (W) • Shanghai 200040 DEUTSCHLAND: Alte Ziegelei 2–4 • D-51491 Overath DUBAI: DAFZA Office 5AE 722, P.O. Box 293671 • Dubai, United Arab Emirates INDIA: C-20 Community Centre • Janakpuri, New Delhi 110 021 ITALIA: Via Arese, 12 • 20159 Milano SINGAPORE: No. 48 Toh Guan Road East #05-123 • Enterprise Hub • Singapore 608586 UNITED KINGDOM: Regent Business Centre • Jubilee Road • Burgess Hill, West Sussex RH15 9TL Magnetrol® & Magnetrol logotype and Thermatel® are registered trademarks of Magnetrol International. Hastelloy® is a registered trademark of Haynes International, Inc. HART® is a registered trademark of the HART Communication Foundation Modbus® is a registered trademark of Gould, Inc. Monel® is a registered trademark of Special Metals Corporation (Formerly Inco Alloys International) Copyright © 2009 Magnetrol International. All rights reserved. Printed in the USA. Bulletin: 54-100.2 • Effective: July 2005