Special Applications Series: Critical Ethylene Level and Flow Applications and Case Studies Maintaining Safety, Reliability and Productivity In ethylene plants, balancing environment, health, and safety is essential while maximizing productivity. Level and flow instrumentation will assist in preventing loss of primary containment and maintaining a safe environment inside of the tank. That’s critical, because incident consequences are significant, with the direct cost of a work-related death of $1M and indirect costs approximately 4 times greater.* In addition, there is the lasting damage to your brand reputation and the compromised safety of the local community. Instrumentation can also assist in maximizing productivity, including interface type measurement in some of the harshest environments. Today, conformance to IEC 61508 is the standard for reliability. Instruments with the appropriate SIL requirements are suitable for use in SIL 1, SIL 2 or SIL 3 safety loops as a single device or with redundancy. This brochure contains a wide spectrum of Magnetrol® and Orion Instruments® level and flow products that conform to the latest safety standards, including SIL requirements, to assist in the most critical applications in ethylene plants. *National Safety Council’s “Injury Facts” via Chemical Processing M

Ethylene Process Flow Diagram This diagram depicts a typical ethylene plant and indicates key applications. CGC Stage 5 Acid Gas Removal (Scrubber) Quench Tower/Settler Drying Unit Ethylene Storage Acetylene Reactor Demethanizer Column Deethanizer Column Propylene Storage 5. Lubrication Fluids Ethane Cracker Flares 6. Power/Utilities Depropanizer Column Debutanizer Column Gasoline Storage Key Applications 1. Quench Tower/Settler 2. Fractionation Towers 3. Liquefied Gas Storage/Cryogenic 4. 4. Tank Blanketing 5. Lubrication Fluids 6. Power/Utilities 2

Quench Tower/Settler Application: • Feedstock comes into the plant and goes through the ethylene furnaces (pyrolysis) • Once cracked into a variety of hydrocarbons and hydrogen, it immediately begins to recombine into larger molecules • To prevent these reactions, the cracked vapor goes through the quench towers to cool using oil or water • The largest hydrocarbons are carried with the water into the quench settler or the quench water separation drum (QWSD) Challenges: • of control of interface will reduce ethylene production due to inefficient Loss quench tower operation • As feedstock is increased,...

TOWER Application: • Separating substances based on differences in volatilities/ boiling points Challenges: • Level measurement at the bottom of a distillation tower controls the "bottoms" product rate • Poor level control could allow liquid to back up over the stripping trays causing damage and reduced yields • Level that's too low may cause pump cavitation Instrumentation Solutions: • Eclipse® Model 706 Guided Wave Radar Transmitter • Digital Displacer E3 Modulevel Liquid Level Transmitter • Aurora® or Atlas™ Magnetic Level Indicator REBOILER Application: • Provides heat to the bottom of a...

Liquified Gas Storage/Cryogenic Application: • liquids are cooled at normal atmospheric pressure while others require Many pressurization • Feedstock to an ethylene plant’s fractionation towers contains a liquid cryogenic hydrocarbon mixture as a result of going through compression and refrigeration trains after the quench tower Above or below-ground insulated storage tanks are built to specifically hold liquefied gases and minimize evaporation Instruments contend with pressurization, extreme low temperatures and low dielectric media Instrumentation Solutions: Eclipse® Model 706 Guided Wave Radar...

Lubricating Fluids Application: • Liquids used for barrier or buffer fluids are essential in maintaining proper operation of equipment requiring mechanical moving parts, such as pumps At a minimum, low level indication is required to ensure there is liquid in the vessel or seal pot Newer standards, such as API 682 Revision 4, are moving towards continuous measurement utilizing transmitters Instrumentation Solutions: Eclipse® Model 706 Guided Wave Radar Transmitter Echotel® 961 and 962 Single and Dual Point Ultrasonic Level Switches Power/Utilities Application: • Heat Recovery Steam Generator...

Case Study 1 Company: One of the world's largest oil & gas and petrochemical companies headquartered in Europe Challenge: Problems occurred with multiphase applications involving hydrocarbon level with water bottoms and gas vapor space. Guided wave radar was being used, but it did not produce a reliable signal throughout the length of the probe and the interface made it difficult to distinguish between upper level and water below. This threatened LOPC due to error in measurement. Solution: ECLIPSE® Model 706 was found to be best-in-class guided wave radar when tested side-byside. It tracked level...

Radar Eclipse® Model 706 Guided Wave Radar Transmitter Pulsar® Model R86 (26 GHz) Pulse Burst Radar Transmitter Pulsar® Model R96 (6 GHz) Pulse Burst Radar Transmitter Thermal Dispersion Thermatel® Model TA2 Thermal Mass Flow Meter Thermatel® Models TD1 and TD2 Flow/Level/Interface Switches Ultrasonic Echotel® 961 Single Point Ultrasonic Level Switch Echotel® 962 Dual Point Ultrasonic Level Switch Buoyancy Digital E3 Modulevel® Liquid Level Displacer Transmitter Model A10 Single-Stage Displacer Switch Magnetostrictive Jupiter® Model JM4 Magnetostrictive Level Transmitter Magnetic Level Indicators Aurora®...