Author: nicklansdell

Heat, shimmering, stifling, suffocating heat; that may be one of the first things that springs to mind when you think about the oil-rich countries of the Middle East, such as Qatar, Abu Dhabi and Saudi Arabia. The next thought may well be wealth, which has fuelled very fast and extensive development. Heat and wealth have proven very important to manufacturers of heat monitoring instrumentation. For example, Contrec’s 212 Heat Calculator is paving the way across the region in a wide range of applications from Qatar’s Pearl to Ski Dubai, calculating the energy used to cool these luxurious and dynamic buildings in the heat of the desert.

One of the most striking new developments in the region is the artificial island network of Pearl-Qatar, in Doha. When the whole project is complete the Pearl Lagoon will have more than 13 artificially constructed islands featuring luxury villas, apartments and five-star hotels, as well as shops, restaurants and entertainment facilities. The initial estimated construction cost of the project when it was first revealed in 2004 was $2.5 billion. It is now believed that the final cost will be in the region of $15 billion. There are 125 systems operating Contrec’s 212 Heat Calculator in the Pearl to date.

The World Trade Centre in Abu Dhabi is one of 330 such centres in nearly 100 countries around the world, all with the common purpose of facilitating and developing international trade and business. Designed by world-renowned architects Foster and Partners the striking building is a fully integrated mixed-use development with offices, residences, as well as having a hotel, retail mall and a traditional souk. It also features 90 heat monitoring systems with the Contrec 212.

Skiing and deserts do not necessarily go together. However, Ski Dubai opened in 2005 offers five runs, of varying difficulty, height and steepness. The longest run is 400 metres with a descent of 60 metres, making it the first ever indoor black run. Skiers and snowboarders of all skill levels are welcome, and so are those, adults and children alike, just wishing to experience snow for the first time in the world’s largest indoor snow park. There are even penguins at Ski Dubai, giving people the opportunity to meet these Antarctic birds first-hand. It takes a lot of energy to create enough snow to service this enormous 22,500 square metre construction and to keep it cool; 60 Contrec 212 Heat Calculators have been installed to monitor this energy consumption.

Dubai Metro, with 47 stations and two transfer stations, has also installed Contrec’s 212 Heat Calculators. With a daily average temperature of 360C (960F) in the summer, with the highest temperature recorded 52.10C (1260F), Dubai needs to keep cool. Stations, trains, shopping malls, offices and homes all have air conditioning.

Saudi Arabia, with similar temperatures, faces these same challenges. The King Abdulaziz International Airport, just north of Jeddah the largest city of Western Saudi Arabia, was opened in 1981 and is the country’s busiest airport. As well as serving this wealthy and dynamic city it is also the gateway to Islam’s holy city of Mecca, which explains its size and its footfall. The Hajj Terminal has been designed to handle the vast numbers of pilgrims visiting the country to take part in the rituals associated with the annual Hajj and can accommodate 80,000 travellers at the same time.

The Hajj Terminal is known for its tent-like roof structure with ten modules, each consisting of 21 tents of white coloured Teflon-coated fibreglass fabric suspended from pylons. There are 55 systems with Contrec 212 Heat Calculators in this striking building.

Contrec’s 212 Heat Calculator is ideal for these applications. It is designed to measure the energy consumed in chilled water cooling systems and supplied complete with temperature probes. It has the capacity to interface with a wide range of flowmeters, including positive displacement and inferential water meters, magnetic flowmeters and pulse outputs, turbine and paddle wheel flowmeters.

International boundaries are not a problem for the Contrec 212, with its multilingual capability. Data-logging and peak/off peak operations are standard. With accuracy to OIML R75 Class 4 and EN1434 it has the standardised accuracy that meets European and International approvals for heat calculators. In addition its inherent flexibility allows the 212 to also measure the energy consumed in hot water heating systems.

Contrec’s 212 Heat Calculator is a flexible and reliable instrument that enables businesses across a broad range of sectors to monitor the energy consumed in maintaining a pleasant temperature for employees, residents, customers and travellers alike; even in the heat of the desert.

People function at their best when they are comfortable, at work, when shopping and at home. But finding a comfortable temperature to suit everyone is not always easy, especially when the outside temperature can vary widely. Heating and air-conditioning systems are used around the world to help create the optimum working and living environment, but how much energy are they using?

In a temperate climate such as that in the UK, heating is most commonly used, with the air-con rarely required, however in the tropics it’s a different situation. Needless to say, whether you’re heating a building or cooling it down, each process costs and to ensure each tenant or resident receives the correct bill a reliable and approved monitoring instrument, such as Contrec’s 212 Heat Calculator, is essential.

Most large office buildings house several tenants, some even sharing the same floor. When this happens it is vital that each tenant is billed for their own energy use, and no-one else’s. By installing a system that incorporates the 212 Heat Calculator the energy consumed in hot water heating systems and chilled water cooling systems is measured accurately. This instrument meets European and International approvals for heat calculators and has accuracy to OIML R75 Class 4 (Organisation Internationale de Métrologie Légale) and EN1434.

There are 50 such systems in Riverbank House, situated on the River Thames in central London. Within the city’s financial district this multi-award winning ten-storey building provides 29,000m2 of high quality office space. RBC Wealth Management and Man Group Plc have their offices in Riverbank House.

It incorporates a number of innovative features such as sensor controlled revolving glass doors, which lead into a large double-height reception area and a multi-layered system of vibration-reducing rubber blocks to minimise disturbances between floors. Designed by David Walker Architects Riverbank House was shortlisted for a 2011 RIBA Award.

The average daily temperature in London, at the height of summer in July, is a mere 190C (670F). It drops to an average of only 70C (440F) in the winter in December, January and February. It is very different in Singapore, which has a tropical rainforest climate with very little seasonal variation. It’s always hot, it’s always humid and it rains a lot in Singapore. With daily average temperatures of around 300C (860F) dropping only as far as 230C (730F) at night heating is rarely required, however air-conditioning is essential for comfort.

There is no doubt that hospitals need to be comfortable to ensure the best outcome for patients and create the best working environment for staff. In 2012 construction started on a new 700-bed hospital located in the Western part of Singapore. The Ng Teng Fong General Hospital, named after a Singaporean entrepreneur, is part of an integrated development, which also includes the construction of the 400-bed Jurong Community Hospital. It is estimated that the development will cost in the region of 635 million Singaporean Dollars (over £300 million).

These are the first hospitals in Singapore to be designed and built together from the ground up. They’ve been created as an integrated development to complement each other for better patient care, greater efficiency and convenience. They’ve been designed to ensure patient-centred services are delivered in a seamless and integrated way. They also incorporate a wide range of innovative technologies, including 300 Contrec 212 systems to calculate the energy used in the air conditioning units.

Contrec’s 212 Heat Calculator is flexible and therefore ideal for both of these very different applications. It is supplied complete with temperature probes and has the capacity to interface with a wide range of flowmeters, including positive displacement and inferential water meters, magnetic flowmeters and pulse outputs, turbine and paddle wheel flowmeters.

International boundaries are not a problem for the Contrec 212, with its multilingual capability. Data-logging and peak/off peak operations are standard. The 212 can be supplied with two precision 4-wire Pt100 RTDs (resistance temperature detectors) and has inbuilt correction for the non-linearity of the RTDs. For chilled water measurement where the temperature difference (Δt) is likely to be small, provision is made in the set-up program to zero out any offset between RTDs. It is fully programmable and all set-up data and totals are stored in a non-volatile memory for a minimum of 10 years.

Contrec’s 212 Heat Calculator is a flexible and reliable instrument that enables everyone from financiers to healthcare professionals to monitor the energy consumed in maintaining a pleasant and comfortable temperature. Whether it’s heating in London or air-conditioning in Singapore the 212 has it covered.

The North West Shelf Project is Australia’s largest resource development. Owned by an international consortium of six partners it is a major producer of liquefied natural gas (LNG), natural gas, liquid petroleum gas, condensate, which is a light crude oil, and crude oil. It has supplied Australia’s domestic market since 1984, supplying 65% of Western Australia’s domestic gas and accounting for more than 40% of Australia’s overall oil and gas production. Since 1989 it has also supplied the Asia Pacific Region delivering over 4,000 LNG cargoes in the last 25 years. It has very close links with Japan, South Korea and China.

Its offshore production facilities include the North Rankin Complex, which is one of the world’s largest offshore gas facilities, the Goodwyn A and Angel Platforms and the Okha floating production storage and offloading vessel. The project also includes the onshore Karratha Gas Plant, which is one of the most advanced, integrated gas production systems to be found anywhere. It covers approximately 200 hectares and has a LNG production capacity of 16.3 million tonnes a year. With investments of over $30 billion in the last thirty years it is the sixth largest LNG producer in the world in terms of LNG plant capacity.

Located on the Burrup Peninsula, near the Port of Dampier, and 1,260 kilometres north of Perth, the vast undersea natural gas and crude oil reserves in the Carnarvon Basin require specialist equipment to ensure safe and efficient operations. For example, the Contrec 515-A101 Additive Injection Controller has been specifically designed and manufactured to overcome the challenges of operating in this demanding environment and with the additional challenges created by the need for pulsating dosing pumps.

A new 14 kilometre stretch of undersea pipeline has been constructed, which has to be pre-commissioned, flooded, pigged and treated before use. The integrity of a pipeline is paramount. Pigging before a pipeline is operational can ensure that any debris accumulated during construction is removed, seawater is flushed out and corrosion inhibitors are used to coat the entire length of the pipe before production commences. Keeping the pipeline clean is essential for efficient flow.

The new undersea North West Shelf required an automated system to control the injection of a corrosion inhibitor at 500ppm and dye at 50ppm with the integration of specialist alarms in the main pumping system. Without an existing system that fulfilled these specific requirements or one that could handle the difficult nature of pulsating dosing pumps Contrec Systems, based in Melbourne, has worked with a number of manufacturers to create a bespoke solution.

The Contrec 515-A101 Additive Injection Controller combines the Contrec 515 with a suitable hardware platform and existing flow measurement and control modules. The control system has been positioned and wired into stainless steel enclosures with the skid and additive lines designed and built to meet the customer’s requirements.

In testing the main flow was simulated and water used as the additive mediums. The nature of the pumps specified required 4-20mA control, which introduced more inherent variability in the system. With the use of flexible parameters the challenges posed by the change in fluid dynamics and inherent delays were addressed and the system was able to track the target ratio within a few PPM. Error conditions were simulated and the appropriate alarms and exceptions were raised.

More rigorous trials were then conducted in Perth where the Contrec 515-A101 was integrated into a more comprehensive setup and tuned to the main pump and pigging system. Although a pulsation dampener had been included in the additive lines to great effect, a four or five point non-linear curve will be implemented in the completed solution to allow for further tuning of the system for its variable flow range.

Contrec’s specialist engineers have been involved at every stage of development, designing and manufacturing the application and then through to the commissioning, trialling and tuning of the system to ensure it meets the client’s exacting requirements.

Established over thirty years ago to develop the first electronic flowmeter displays for Shell in Australia Contrec is proud to be the benchmark for process and petroleum instrumentation. With products designed and developed to operate in all sectors of the oil and gas industry Contrec supplies instrumentation to upstream, midstream and downstream applications across the world. Products are fully certified to ISO9001:2000 and equipment carries the latest approvals for use in hazardous areas.

Compressed air uses more electricity than any other type of equipment in a production plant. It can account for 20% of a company’s overall energy costs. This is not surprising considering the myriad of uses it has in many manufacturing processes and the number of compressors that may be used in a large compressor system. Monitoring compressed air usage can be the first step in creating a more energy efficient system overall, explained Pam Casson Managing Director of Contrec Ltd

By measuring compressed air consumption leaks can be identified and dealt with immediately, it can ensure the correctly sized compressors are being used in the best places, at the right times, and it can reduce the overall plant consumption. This could reduce overall energy usage, lower a company’s carbon footprint and save thousands of pounds a month in large industrial plants.

There are a number of different Contrec instruments, which can be used to monitor compressed air depending on the specific flowmeter used. For example, CML’s 515 GC01 application is ideal as it measures the volume, corrected volume and mass of a general gas. The instrument uses a frequency volume flow input and analog temperature and pressure sensor inputs. It is compatible with a wide range of flowmeter frequency outputs. Millivolt signals, reed switches, Namur proximity switches or pulse trains can be selected via its smart front-panel programming.

The properties of a gas are calculated using common industry standard equations of state: Ideal Gas, Redlich-Kwong, Soave-Redlich-Kwong and Peng-Robinson. These equations use a simplified set of parameters to quickly and accurately determine the value of compressibility and actual quantity of gas. A variety of calculations are available to suit the nature of the gas and the measurement conditions.

Its many features include its ability to allow quadrative flow input for ISO6551 level B pulse security and its non-linear correction capability. The front panel display shows the current values of the input variables and the results of the calculations. It can be supplied with a real-time clock for data logging of over 1000 entries of the variables as displayed on the main menu.

Contrec is an independent specialist manufacturer of flow computers, batch controllers and flow rate totalisers for the flow meter industry. Contrec can provide a wide range of solutions, from the 120A Level Monitor, which offers four level alarms and accepts a 4-20mA signal from a number of different level sensors, to the 515 BR01 Frequency Input Batch/Ratio Controller that is tailored for volumetric frequency flow input. CML also has the capability and expertise to engineer a complete system, from design and creation to installation and commissioning.

Contrec provides flow instrumentation for the petroleum industry, off-shore pipelines, gas, air, water and energy, as well as the food and beverage industries. In process industries flow meters are used for a wide range of applications, such as accurate chemical dosing, metering of additives, leak detection and measurement of incoming water usage. The company supplies its products to service centres in Australia and the USA and its many distributors around the world, including several key original equipment manufacturers.

Compressed air is used in many manufacturing processes for many different reasons, from the actuation and control of pneumatic valves and cylinders to the operation of process machinery and tooling. It can also be used as a transport medium for bulk materials or as a purge gas. For all its uses it is nonetheless expensive. This is why, through detailed monitoring, a business can enjoy the financial, environmental and operational benefits of an efficient and effective compressed air system.

Typically compressed air uses more electricity than any other type of equipment in a production plant. It can account for 20% of a company’s overall energy costs. This is not surprising considering the myriad of uses it has in many manufacturing processes and the number of compressors that may be used in a large compressor system. By measuring compressed air consumption leaks can be identified and dealt with immediately, it can ensure the correctly sized compressors are being used in the best places, at the right times, and it can reduce the overall plant consumption. This could reduce overall energy usage, lower a company’s carbon footprint and save thousands of pounds a month in large industrial plants.

With faster and more accurate pressure controls it is possible to maintain a lower average pressure in the whole system as it is no longer necessary to keep a higher pressure in order to maintain the minimum level required. Fluctuations are smaller, the control range narrower and the overall consumption reduced. Narrower variations in power also make it possible to avoid negative effects on production quality control.

But of course very few air systems operate at full-load all of the time. It is therefore essential to have the ability to implement a strategy of part-load performance, through system-wide and individual compressor controls, to suit the requirements of the plant. These can take the form of start/stop, load/unload, modulating, multi-step or variable frequency drives for individual compressors. For system controls these can include single master, sequencing controls; multi-master, network, controls; flow controllers; or air storage.

In addition to maintaining the optimum pressure level in all parts of the system it is also crucial to ensure the quality of the compressed air itself. Compressed air contains moisture. If this is not controlled it may cause damage to the process, the product or even the components of the air distribution system. To reduce the moisture content refrigerant dryers are used to cool the air in a heat exchanger. When the temperature is just above the freezing point of water the moisture in the air will condense to a liquid, which can be drained off. Maintaining good temperature control is critical for the efficient operation of the dryer as too low, below 320F, ice will form instead of water. An accurate temperature gauge is needed to make sure the dryer is functioning correctly.

There are a number of different Contrec instruments, which can be used to monitor compressed air depending on the specific flowmeter used. For example, Contrec’s 515 GC01 application is ideal as it measures the volume, corrected volume and mass of a general gas. The instrument uses a frequency volume flow input and analog temperature and pressure sensor inputs. It is compatible with a wide range of flowmeter frequency outputs. Millivolt signals, reed switches, Namur proximity switches or pulse trains can be selected via its smart front-panel programming.

The properties of a gas are calculated using common industry standard equations of state: Ideal Gas, Redlich-Kwong, Soave-Redlich-Kwong and Peng-Robinson. These equations use a simplified set of parameters to quickly and accurately determine the value of compressibility and actual quantity of gas. A variety of calculations are available to suit the nature of the gas and the measurement conditions.

Its many features include its ability to allow quadrative flow input for ISO6551 level B pulse security and its non-linear correction capability. The front panel display shows the current values of the input variables and the results of the calculations. It can be supplied with a real-time clock for data logging of over 1000 entries of the variables as displayed on the main menu.

There are two communication ports available: RS-232 port (standard) and RS-485 port (advanced option). The ports are available for remote data reading, printouts and for initial application loading of the instrument.

As with many Contrec instruments the 515 GC01 application offers a wide range of options, which can be further tailored to suit specific application needs, including units of measurement, custom tags, second language or access levels.

Contrec offer a range of options for compressed air flow measurement, for more information email sales@contrec.co.uk

There are many types of storage tanks, each with particular design and manufacture specifications depending on the type of liquid or gas to be contained. Safety is paramount. Failure to ensure the highest safety standards can have disastrous results for employees working in close proximity to the tank, for people and property further afield and also the environment. Major incidents, such as the Boston Molasses Disaster in 1919 and more recently the Buncefield Oil Storage Depot Incident in 2005, demonstrate the dangers of failures in safety procedures but also provide lessons for the future.

Storage tanks can be situated above ground or underground with different regulations on their design and operation, depending on their location and use. To contain potential leakages, tanks will be surrounded by a containment dike or bunding, or will be bunded, offering a ‘second skin’. Bunded fuel tanks are required by law for any volume of fuel over 200 litres on a commercial property.

The type of liquid to be stored has implications for the design and manufacture of the tank itself. Tanks can have fixed roofs, floating roofs or both, with an internal floating roof and fixed roof above. Internal floating roofs are a safety requirement for use in many industries, such as oil refineries. They are used for liquids with low flash points, for example gasoline or ethanol, and have a cone roof with a floating roof inside that travels up and down along with the liquid level. This floating roof traps the vapour from the low flash point fuel to minimise the risk of ignition.

Tanks with only a floating roof and no fixed roof above, just an open top, are designed for medium flash point liquids, including kerosene, diesel and crude oil. And fixed roof tanks can contain high flash point fuels such as fuel oil, water and bitumen. These can have cone, dome or umbrella roofs.

Storage tanks perform essential functions in many industries, from refineries to agricultural settings, not just holding liquids and gases but in some cases storing them at specific temperatures. But any tank can be a hazard if not properly manufactured or maintained or if the correct procedures have not been followed. And damage to the tank, pipework or fittings can cause the contents to leak and create a dangerous situation, none more so than with highly flammable liquids. However, even molasses can be deadly, as demonstrated in Boston in 1919, when 21 people were killed when a tank failed due to poor design and quality.

More recently the Buncefield Oil Storage Depot Incident, in which two people were seriously injured, highlighted the essential role that flow equipment plays in ensuring the safe operation of storage tanks. The Buncefield Standards Task Group found that the two forms of level control both failed resulting in the overflow of large quantities of petrol. A large vapour cloud formed which ignited causing a massive explosion and a fire that lasted for five days.

In the task group’s final report the need for an overfill prevention system was highlighted. This should include equipment that provides sufficient separation between the maximum capacity of the storage tank, to avoid loss of containment, and the tank rate capacity, the level at which the alarm needs to be raised to prevent the maximum capacity, in other words the overfill level, from being reached or exceeded. This separation should take into consideration the possible need to operate a manual over-ride, which due to circumstances on the site may potentially be sited in an inaccessible position or which otherwise may require longer to operate.

Contrec’s 505 LM01 single tank level monitor is designed to give advanced warning as it monitors and measures the level of product in a single tank. The instrument uses the 4-20mA signal from a wide range of level sensors, including pressure transmitters, ultrasonic sensors and capacitance probes. The level monitor provides a 20 point strapping table and product density for level to volume and volume to mass conversions. It can display volume, percentage full and mass as well as level. Relay alarms are freely assignable as high or low alarms and an open collector output is provided for programmable level control.
A sub-menu gives full details of alarm status and can offer direct access to change the alarm setpoints. The instrument also has density correction available for pressure level sensors to cater for a deviation in product density. The relay alarms can be assigned to any of the main menu variables of a rate type. The alarms can be fully configured including hysteresis.

As with many Contrec instruments the 505-LMO1 can be further tailored to suit specific application needs including units of measurement, custom tags, second language or access levels.