Introduction
 Sugar Solution Leak Monitoring |
In the past, the boiler feed tank systems in sugar factories had to be checked several times a day to make sure there were no sugar solution leaks. This was a very laborious process and, as continuous monitoring was not possible, monitoring results were not reliable. When a leak occurred, recovery operations were very costly and time-consuming.
With the FLXA202 and FLXA402 inductive conductivity analyzers, these are now problems of the past: both devices enable stable, continuous monitoring and the quick detection of sugar solution leaks, preventing serious problems from ever developing.
Expected Benefits
- Automatically detect sugar solution leaks in sugar factories
- Reduces operating costs
Process Overview
In sugar factories, crystallizers and concentrators produce a large amount of steam drain, which is reused as boiler feed water. However, sugar leaked during the boiler feed process can mix into this water. When that happens, the sugar can decompose into an organic acid at high temperatures, thereby decreasing the pH of the water. If the boiler operates with water at a low pH level, it can become corroded. The lowered pH needs to be raised to a normal level by performing a blowdown or the like, and the losses potentially caused by this process are not necessarily small. The sugar solution leak must be quickly detected before a minor problem turns into something much worse. For this reason, continuous monitoring is essential.
Solution Details
Measurement system
2-wire inductive conductivity system
| Sensor: | ISC40G(J)-GG-T1-☐☐ |
|---|---|
| Transmitter: | FLXA202-D-BｰD-☐-C5-NN-A-N-LA-☐-NN |
| Dedicated distributor for transmitter: | PH201G-A☐*B |
4-wire inductive conductivity system
| Sensor: | ISC40G(J)-GG-T1-☐☐ |
|---|---|
| Converter: | FLXA402-A-B-☐-C5-NN-A2-WR-☐-☐-☐-NN |
Field Data
Process conditions
Steam return line of crystallizer outlet
| Measurement liquid: | steam drain (plus sugar solution) |
|---|---|
| Monitoring range: | 0 - 200 μS/cm |
| Temperature: | approx. 80 °C |
| Alarm point: | 100 µS/cm |
(contact output can be used with the FLXA402)
 |
| Sugar Solution Leak Condition |
Utilities
FLXA202 inductive conductivity transmitter
| Power supply voltage: | 17 - 40 V DC (from distributor) |
|---|
PH201G distributor
| Power supply: | 100 V: 20 to130 V DC/80 to 138 V AC, 47 to 63Hz 220 V: 120 to 340 V DC/138 to 264 V AC, 47 to 63 Hz |
|---|---|
| Power consumption: | 24 V DC: approx. 200 mA 100 V AC: approx. 7 VA 220 V AC: approx. 11 VA |
FLXA402 inductive conductivity converter
| Power supply: | 90 to 264 V AC, 50/60 Hz |
|---|---|
| Power consumption: | 35 VA |
Cautions
As the contact output of the PH201G is always magnetically excited, it should be kept closed even when the power is turned off to perform maintenance.
Industrie
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Food & Beverage
At Yokogawa, we understand that today’s food and beverage companies face unprecedented challenges in climate change, consumer demand, and increased global competitiveness. Overcoming these challenges will require innovative solutions that focus on key areas of production, asset management, and food safety and quality.
Prodotti e Soluzioni Correlati
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2-Wire Transmitter/Analyzer FLXA202
The FLEXA™ series analyzers are used for continuous on-line measurements in industrial installations. With an option for single or dual sensor measurement, they are the most flexible two-wire analyzer available.
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2-Wire Transmitter/Analyzer FLXA21
The FLEXA™ series analyzers are used for continuous on-line measurements in industrial installations. With an option for single or dual sensor measurement, they are the most flexible two-wire analyzer available.
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High Conductivity Sensors ISC40/SC42
The measurement of specific conductivity in aqueous solutions is becoming increasingly important for the determination of impurities in water. Yokogawa has designed a full range of precision sensors and instruments to cope with these measurements, even under extreme conditions.
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Hot-Tap Holder PR10
On-line measurements often present extra challenges, especially when routine maintenance is required. The PR10 is ideally suitable for applications where the sensors must be removed without interrupting or shutting down the process. Without any special tools the PR10 can be retracted safely from the process at pressures up to 5 bar (72 psi). Using the PR10 allows us to place any dissolved oxygen sensor that has a PG13.5 connenction into a retractable assembly.
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Inductive (Torodial, Electrodeless) Conductivity Sensor ISC40
The model ISC40 sensors are designed for use with the FLEXA ISC analyzers. This combination exceeds all expectations for conductivity measurement in terms of reliability, accuracy, rangeability and price performance.
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Multi Channel 4-Wire Analyzer FLXA402
The FLEXA™ series analyzers are modular-designed analyzers used for continuous online measurements in industrial installations. They offer single or multi-sensor measurement.
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Percent Concentration Sensors ISC40
There are numerous industrial applications where measurements and/or control of a specific chemical strength of the process is critical for optimizing the production of the end product. These specific concentrations are obtained by mixing a full strength solution with water to achieve the desired percent concentration.
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Conductivity Analyzers
Conductivity meters, analyzers and transmitters are used for continuous process measurement and monitoring of conductivity, resistivity, WIFI, demineralizer water, RO water, percent concentration, boiler blowdown and TDS.
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Conductivity Sensors
Conductivity sensors and electrodes are used to measure process conductivity, resistivity, WIFI, demineralizer water, RO water, percent concentration, boiler blowdown and TDS. Various installation options including retractable, flow thru, immersion, and direct insertion. Proper electrode/sensor selection is critical for optimal measurement results.