Oxygen Flow Made Simple by EPI Thermal Mass Meters

Eldridge Products Inc. (EPI) designs thermal mass flow meters that deliver reliable and precise oxygen measurements in various industrial applications. Many processes demand accurate oxygen flow data because even a slight deviation from optimal levels can affect combustion efficiency, degrade wastewater treatment outcomes, or compromise the consistency of industrial gas delivery. EPI addresses these critical demands by developing thermal mass flow meters that respond quickly to changes in flow and handle the unique challenges posed by oxygen’s physical and chemical properties.

Oxygen’s low density and high reactivity often create issues for traditional flow measurement methods. Some meters fail to read low flows accurately, and others require long straight-run sections to stabilize velocity profiles. EPI reduces these complications by incorporating Flow Averaging Tube (FAT) technology, which ensures consistent velocity sampling across the entire cross-section of the pipe. Operators gain stable, repeatable measurements even when space constraints limit the availability of long straight runs. This advantage proves especially valuable in facilities that must retrofit existing infrastructure or fit meters into tight layouts.

EPI’s thermal mass flow meters use a heating element and temperature sensors that interact with the moving gas stream. Their direct mass flow measurement principle captures the mass of oxygen flowing through the pipe rather than inferring mass from volume and temperature data. This approach eliminates additional pressure or temperature compensation, making installation and maintenance more straightforward. Operators who rely on these meters notice high turndown ratios, allowing the instrument to measure very low and very high flows with minimal compromise on accuracy. This versatility becomes essential in applications like combustion control, where oxygen demand can fluctuate drastically during startup, steady-state operation, and shutdown phases.

Wastewater treatment plants also benefit from this robust turndown capability because aeration requirements shift over time, and the process does not always follow a uniform flow profile. EPI’s meters adjust to these dynamic conditions and provide precise data that helps operators fine-tune aeration rates. When plants achieve this level of control, they save energy by avoiding excessive oxygen injection while meeting strict effluent quality standards. Over-aeration leads to wasted energy and higher costs, so tighter oxygen monitoring pays off economically and environmentally.

Medical and pharmaceutical processes depend on clean, accurately measured oxygen delivery, and EPI’s thermal mass flow meters adapt well to those scenarios. The stable sensor design measures gas flow without imposing a significant pressure drop, which helps maintain system integrity and product quality. Because thermal mass flow meters require little routine calibration, operators spend less time performing maintenance tasks that disrupt critical procedures. Minimizing downtime takes priority in any high-stakes environment, and the reliability of EPI’s instruments supports that goal.

Operators who install EPI’s thermal mass flow meters often report simpler setups and lower total cost of ownership. The sensors feature robust construction that resists corrosion and does not rely on moving parts that would degrade in corrosive environments. The intuitive user interface allows quick adjustments when flow patterns change, and remote monitoring options offer immediate visibility into real-time gas consumption. These features contribute to smoother overall operation and heightened confidence in the accuracy of oxygen flow measurements.

EPI recognizes the importance of maintaining stable processes in industries that work with oxygen, and it consistently refines its thermal mass flow meters to meet evolving demands. By leveraging FAT technology, achieving high turndown ratios, and offering minimal straight-run requirements, EPI flow meters help facilities capture accurate flow data, optimize oxygen usage, and ensure safe, reliable operation. This commitment to innovation and practical design underlines EPI’s reputation as a trustworthy partner for organizations that rely on precise oxygen flow measurement.

https://process-tech.com
801-264-1114

Powering Safety and Innovation in Industrial Process Environments

Process Technology, Inc. in Salt Lake City, UT, delivers various products and solutions for industrial process control and automation. The company partners with industry-leading manufacturers to provide instrumentation, measurement devices, and integrated control systems that help customers optimize their operations in the Southwest, Frontier Range, and Mountain West regions. Engineers, technicians, and plant managers rely on Process Technology, Inc. for robust solutions that improve safety, increase efficiency, and reduce downtime.

Flow measurement devices represent a core offering in the company’s product portfolio. These meters help users accurately track liquids, gases, and slurries. In many industries—such as water treatment, mining, and chemical processing—precise flow data prevents material waste and ensures regulatory compliance. Process Technology, Inc. supplies ultrasonic, magnetic, Coriolis, and vortex flow meters, among other technologies, to meet different application needs.

The company also offers level measurement solutions for tanks, silos, and other vessels. Accurate level readings are critical in industries that store solids or liquids in bulk. Process Technology, Inc. helps operators maintain efficient inventory management and avoid overflows or supply shortages by equipping facilities with radar, guided wave radar, capacitance, or ultrasonic level transmitters.

Process Technology, Inc.'s pressure and temperature instrumentation covers both routine and extreme environments. Oil and gas, food and beverage, and power generation operators rely on these sensors to ensure equipment remains within safe operating limits. Process Technology, Inc. stocks a variety of gauges, transmitters, and switches that provide real-time insights into process conditions.

Industrial facilities often need advanced gas detection and analytical equipment to maintain compliance and protect workers. Process Technology, Inc. supplies analyzers that detect hazardous gases, measure emissions, and monitor gas purity. Their solutions deliver crucial information for petrochemical refineries, mining sites, and wastewater plants, where personnel rely on accurate data to make rapid decisions.

The company's automation experts provide system integration and engineering support for programmable logic controllers (PLCs), distributed control systems (DCS), and supervisory control and data acquisition (SCADA) platforms. They consult on new builds and retrofits, assisting clients through each project phase. Customers benefit from customized control panels, software programming, and turnkey installations tailored to specific application requirements.

Process Technology, Inc. staff emphasize training and ongoing technical support to help end users operate their equipment safely and effectively. The company’s experts share best practices and technical insights through regular blog articles and online resources addressing process optimization, calibration procedures, and emerging automation trends.

Process Technology, Inc. serves various industries across the Southwest, Frontier Range, and Mountain West territories. Customers count on the company’s deep application knowledge, fast response times, and dedication to reliable service. Process Technology, Inc. remains a trusted partner for facilities that need innovative ways to manage complex industrial processes by offering proven instrumentation, comprehensive automation solutions, and hands-on engineering support.

https://process-tech.com
801-264-1114

Gas Detection in the Modern Industrial Environment

Technicians who measure harmful gases in ambient air face significant challenges and must remain vigilant to ensure a safe industrial setting. Both oxygen deficiency and enrichment create serious hazards, while toxic substances such as hydrogen sulfide, chlorine, and ammonia endanger workers and compromise valuable equipment. A reliable sensor and monitoring system mitigates these risks by automating gas detection and providing reassurance in demanding industrial environments.

Engineers design gas detectors to track specific gases in particular areas, selecting sensing technologies based on the target gas. Electrochemical cells excel at detecting toxic gases, while catalytic bead sensors specifically detect combustible gases. Infrared components provide non-destructive detection of hydrocarbons and other gases that absorb specific wavelengths. Maintenance personnel install these detectors in locations with high probability of gas leaks, such as areas with frequent chemical handling, storage tanks, or pipelines. This placement strategy reflects a proactive approach that emphasizes worker safety and prevents catastrophic accidents from undetected leaks.

Accuracy demands rigorous calibration processes when using gas detection equipment. Technicians perform both zero calibration with clean air to establish baseline readings and span calibration with target gases to verify sensor accuracy at specific concentrations. Regular bump testing confirms proper alarm function and sensor response. These calibration procedures reveal potential sensor degradation and alert operators to emerging issues before sensors lose effectiveness. Networked monitoring systems enhance safety by collecting continuous data and relaying that information to control rooms, with redundant systems ensuring no interruption in critical applications. Building management systems integrate this gas monitoring data to automate ventilation and emergency responses. Operators analyze trends, spot irregularities, and intervene quickly to protect personnel and infrastructure.

Safety protocols encompass more than hardware installation and maintenance. Comprehensive training programs teach employees how detectors operate and how to interpret alarm signals. Organizations document all training, mandate regular refresher courses, and clearly define emergency roles and responsibilities. Technicians learn specific response procedures for different alarm levels, including when to evacuate, when to initiate emergency shutdowns, and how to coordinate with emergency responders. These actions dramatically reduce the probability of explosions, chemical burns, respiratory complications, and other severe injuries from uncontrolled gas exposure.

Gas detection serves a critical role across diverse industries including oil and gas, nuclear power, mining, construction, medical facilities, and food processing. Each sector encounters unique challenges since gas hazards vary according to specific processes. An oil refinery might combat hydrogen sulfide leaks, while a food processing plant handles ammonia in refrigeration systems. Despite these differences, every industry benefits from comprehensive gas detection strategies that combine accurate sensors, dependable alarm systems, and skilled staff members who follow well-established safety practices.

Reliable gas detection equipment creates a safer environment by identifying hazardous conditions before they become dangerous. Workers gain confidence when they know advanced sensors and diligent monitoring keep them informed about otherwise invisible threats. This confidence fosters a culture of responsibility, where teams recognize that active prevention measures protect both employees and the broader industrial infrastructure.

https://process-tech.com
801-264-1114

Season's Greetings and Happy New Year from Process Technology

As the year winds down and we reflect on our shared accomplishments, we all at Process Technology would like to express our sincere appreciation for your trust, partnership, and dedication. Whether you have supported us for many years or partnered with us more recently, your confidence in our mission and capabilities has been essential to our progress and achievements.

To our customers, thank you for inspiring us to continuously enhance our products and services to better meet your evolving needs. To our partners, your reliability, insight, and cooperation enable us to consistently deliver quality and value. To our employees, your skill, enthusiasm, and commitment form the foundation of all we do. Each of you is integral to our success, and we are deeply grateful for your contributions.

As we greet the upcoming year, may you find opportunities to celebrate, connect, and enjoy the things that mean the most to you. Looking ahead, we remain dedicated to building upon our accomplishments, fostering lasting relationships, and working together toward even greater heights.

On behalf of the entire Process Technology team, we extend our warmest Season’s Greetings and best wishes for a bright and prosperous New Year.

Thermal Mass Flowmeters: Advancing Efficiency in Industrial Applications

Thermal mass flowmeters have become indispensable tools in various industries. They provide accurate and reliable measurements of gas flow rates. Their unique operating principles and performance characteristics make them suitable for applications ranging from boilers to wastewater aeration, oxidizers, and flares.

Understanding Thermal Mass Flowmeters

At the core of thermal mass flowmeter technology lies the principle of thermal dispersion. These devices measure the mass flow rate of gases by detecting temperature changes. Two temperature sensors are used: one heated and one unheated (reference). As gas flows over the heated sensor, it carries heat away, causing a temperature drop proportional to the mass flow rate. The flowmeter measures the energy required to maintain the temperature difference between the sensors, thereby calculating the mass flow directly without needing pressure or temperature compensation.

Performance and Advantages

Thermal mass flowmeters offer several advantages over other flow measurement technologies. They provide direct mass flow measurements, eliminating the errors associated with density fluctuations. Their wide turndown ratio allows for accurate readings over a vast range of flow rates, making them ideal for processes with variable demand. Additionally, they exhibit low-pressure drop and minimal intrusion into the flow, preserving system efficiency and reducing energy costs.

Common Applications

In boiler systems, thermal mass flowmeters monitor fuel gas and combustion air to optimize combustion efficiency, reduce emissions, and ensure safe operation. Accurate gas flow measurement enables precise control of the air-to-fuel ratio, leading to energy savings and compliance with environmental regulations.

Wastewater treatment facilities rely on thermal mass flowmeters for aeration control. By measuring the flow of air or oxygen injected into aeration basins, operators can maintain optimal dissolved oxygen levels, promoting efficient microbial activity for waste breakdown. This control reduces energy consumption and enhances treatment performance.

Oxidizers, used to destroy volatile organic compounds (VOCs) and hazardous air pollutants (HAPs), benefit from thermal mass flowmeters in monitoring and controlling the flow of process gases. Precise flow measurement ensures that oxidizers operate within design parameters, maximizing destruction efficiency and minimizing operational costs.

In flare gas systems, thermal mass flowmeters provide critical data for compliance and reporting. Accurate measurement of flare gas helps monitor emissions, detect leaks, and optimize flare performance. The ability to handle low flow rates and variable gas compositions makes thermal mass flowmeters particularly suitable for flare applications.

EPI Thermal Flowmeters: The FAT Probe Advantage

EPI offers advanced thermal flowmeter solutions that address common challenges in industrial applications. Their FAT probe stands out with its ability to perform accurately with as little as 5-7 pipe diameters of straight-run, about half the length required by typical thermal mass flowmeters with flow conditioners. This feature proves invaluable in retrofit projects or installations with limited straight-run piping, where space constraints often hinder the placement of conventional flowmeters.

The FAT probe's design provides engineers with greater flexibility in system layout and reduces installation costs. Its accuracy and reliability remain strong despite the reduced straight-run requirement, ensuring consistent performance in demanding environments. By choosing EPI's thermal flowmeters, engineers can enhance process control, improve efficiency, and achieve compliance with industry standards.

Thermal mass flowmeters are crucial in optimizing industrial processes by providing precise gas flow measurements. Their application in boilers, wastewater aeration, oxidizers, and flares demonstrates their versatility and effectiveness. EPI's innovative thermal flowmeters, notably the FAT probe, offer significant advantages in installations with space limitations. Engineers seeking efficient, reliable, and flexible flow measurement solutions will find EPI's products valuable to their systems.

https://process-tech.com
801-264-1114

Enhancing Safety and Hydrogen Purity in Water Electrolysis with Advanced Gas and Moisture Analyzers

Download Panametrics' white paper titled "Ensuring Process Safety and Product Quality in Water Electrolysis Using Oxygen, Hydrogen, and Moisture Analyzers" to learn how advanced analyzers enhance safety and ensure hydrogen purity in water electrolysis processes.

As the global demand for clean energy intensifies, hydrogen emerges as a promising solution to reduce carbon emissions and transition toward a sustainable future. Water electrolysis, a critical method for producing green hydrogen, requires the highest levels of hydrogen purity. Contaminants can compromise the efficiency of hydrogen as a fuel and the safety of its production and utilization. Gas and moisture analyzers play an indispensable role in maintaining the integrity of water electrolysis processes, ensuring the highest levels of hydrogen purity, and enhancing safety.

Hydrogen's effectiveness as an energy carrier hinges on its purity. Impurities such as oxygen, nitrogen, and moisture can harm hydrogen fuel cells, industrial applications, and storage systems. For instance, oxygen contamination can lead to explosive mixtures, posing significant safety hazards. Moisture can cause corrosion in pipelines and storage tanks, while nitrogen can reduce the calorific value of hydrogen, affecting its performance. Therefore, monitoring and controlling these contaminants become essential for any hydrogen production facility aiming for excellence.

Several factors can introduce impurities into the hydrogen stream in water electrolysis. The water and electrolytes might contain dissolved gases or minerals that transfer into the hydrogen produced. Gas crossover, especially in proton exchange membrane (PEM) electrolyzers, can occur when hydrogen and oxygen permeate through the membrane, leading to cross-contamination. Also, system leaks can allow atmospheric gases to infiltrate the hydrogen stream. Addressing these challenges requires precise and continuous monitoring, where gas and moisture analyzers come into play.

Gas analyzers serve as the first line of defense by detecting and quantifying unwanted gases within the hydrogen stream. They provide real-time data on contaminants like oxygen and nitrogen, enabling operators to make immediate adjustments to the process. For example, if oxygen levels rise beyond acceptable limits, operators can investigate potential membrane failures or system leaks promptly. This proactive approach not only maintains hydrogen purity but also prevents hazardous situations that could arise from combustible gas mixtures, underscoring the preventive role of gas analyzers.

Moisture analyzers, on the other hand, focus on measuring the water vapor content in the hydrogen gas. They play a crucial role in preventing several operational issues. In fuel cells, high moisture levels can degrade the proton exchange membranes, reducing their efficiency and lifespan. Moisture can also freeze in cryogenic systems, causing blockages and equipment damage. By keeping moisture levels within specified parameters, moisture analyzers help prevent corrosion, maintain the performance of fuel cells, and ensure the smooth operation of storage and transportation systems, underscoring their role in preventing operational issues.

Integrating gas and moisture analyzers into water electrolysis setups enhances safety and efficiency. These instruments provide the data necessary to optimize the electrolysis process, such as adjusting the operating conditions to minimize gas crossover or improving the purity of input water and electrolytes. They also help facilities comply with industry standards and regulations regarding hydrogen purity, crucial for applications in sensitive sectors like aerospace, medical, and energy generation.

Moreover, the use of these analyzers contributes to long-term cost savings. Facilities can avoid costly repairs, downtime, and equipment replacements by preventing contamination-related issues. High-purity hydrogen also commands a premium in the market, offering a competitive advantage to producers who consistently deliver superior quality.

The commitment to producing pure hydrogen aligns with the broader environmental sustainability goals and technological advancement. As industries adopt hydrogen as a clean energy source, safety, reliability, and performance expectations continue to rise. Gas and moisture analyzers represent the technological advancements that make it possible to meet these expectations. They embody the precision and control required in modern industrial processes, ensuring the push toward a hydrogen economy is effective and safe.

Gas and moisture analyzers are critical components in the water electrolysis process for hydrogen production. They enable detecting and controlling impurities that can compromise hydrogen purity, safety, and efficiency. These instruments provide real-time monitoring and data analysis, allowing operators to maintain optimal conditions within the electrolysis system. As the world moves toward greater reliance on hydrogen as a clean energy source, the role of gas and moisture analyzers will become even more significant. Investing in high-quality analyzers is a technical necessity and a strategic move supporting achieving a sustainable and carbon-neutral future.

Discover how to enhance process safety and product quality in water electrolysis by utilizing advanced oxygen, hydrogen, and moisture analyzers. Panametrics in-depth white paper explores these analyzers' vital role in maintaining hydrogen purity and optimizing electrolysis processes. Unlock valuable insights and practical solutions to ensure your hydrogen production meets the highest standards. Download the white paper now at https://www.h2-view.com/white-paper/ensuring-process-safety-and-product-quality-in-water-electrolysis-using-oxygen-hydrogen-and-moisture-analyzers/2108903.article/#whitepaperform.

Red Lion Rolls Out High-Performance RTUs for Demanding Industrial Applications

Industrial Remote Terminal Units (RTUs) are critical components in industrial automation and control systems. These devices interface with field equipment, gather data, and transmit it to a central control system. RTUs typically operate in harsh industrial environments, monitoring and controlling machinery, processes, and other systems. They are often used in manufacturing plants to provide real-time data on system performance, enabling operators to make informed decisions that enhance efficiency, reduce downtime, and improve safety.

RTUs have input/output (I/O) interfaces to connect with sensors, actuators, and other devices. They collect data from these sources and communicate it to a supervisory control and data acquisition (SCADA) system or other central controllers via wired or wireless networks. In addition to data acquisition, RTUs can execute control commands, automate processes, and provide remote monitoring capabilities, making them essential for maintaining the smooth operation of industrial processes and ensuring that plants can operate continuously and efficiently, even in remote or hazardous environments.

Red Lion Controls introduced two new programmable Remote Terminal Units (RTUs), the VT-MIPM-138-D and VT-MIPM-248-D, specifically designed to excel in extreme industrial environments. These rugged industrial controllers come with onboard I/O and handle demanding process-oriented applications such as water and wastewater treatment, oil and gas production, and other advanced automation systems.

These RTUs offer robust, standalone control for even the most challenging industrial processes. They feature automatic datalogging, timestamping, and logging capabilities for trends, alarms, and event sequences, providing operators with comprehensive visibility into their operations. Red Lion Workbench’s IEC 61131 programming environment allows extensive programming and troubleshooting, while ISaGRAF support ensures backward compatibility. The units also boast an open system design, supporting Ethernet TCP, Modbus, and Linux.

Ideal for use in water, wastewater, and oil and gas processing facilities, the VT RTUs are pre-certified and allow operators to scale from 1 to over 1000 stations quickly. They feature multi-user connectivity through 10/100 Ethernet ports, RS232 and RS485 interfaces, and up to four communication ports. The onboard I/O includes a mix of digital inputs, digital outputs, analog inputs, and analog outputs. Advanced communication capabilities, such as reporting on exceptions, store and forward, and peer-to-peer networking, further enhance their utility.

Designed for hazardous environments, these controllers are rated for operating temperatures ranging from -40°C to 70°C and carry UL Class I, Division 2, CE, and ABS Type certifications.

For more information about these Red Lion Controls RTUs in Utah, Western Wyoming, Idaho, Northern Nevada, Arizona, New Mexico, Colorado, Eastern Wyoming, and Montana contact Process Technology, Inc.

https://process-tech.com
801-264-1114