Application note

Liquid flow meter data prevents
sugar plant shut down in Algeria

Panametrics’ TransPort* PT878 portable ultrasonic flow meter
performed flow measurements that saved GFD-LaBellehundreds of thousands of Euros in projected total losses.
Challenge
GRD-LaBelle is a raw cane sugar refining mill in Algeria, where 1,000 tons of white
crystallized sugar is produced per day. The sugar manufacturing process involves
ten successive steps, one being the evaporation process that reduces water fromthe filtered juice containing about 15% sugar and 85% water. Boiled when in contactwith steam, the juice passes through a series of evaporators, where temperatureand pressure gradually decrease the water content. At the end of the evaporation
process, the juice is transformed into syrup containing 65 to 70% sucrose.
During this process step, GRD-LaBelle could not recover enough condensates atthe evaporator’s outlet. The initial assumption was that the problem originated in
the upstream area of the condensate receiver tank. Since there are no flow meters
installed in this part of the process to measure recovered condensates, it remained
unclear where the condensates went and so a plant shutdown seemed inevitable..
Condensate recovery vessel anddownstream circuit of the condensatesat the GRD-LaBelle plant

ResultPanametrics' Digital Solutions service engineer in Algeria, Allaoua Felfoul, suggested
that GRD-LaBelle use a portable PT878 ultrasonic flow meter to help diagnose theproblem. Allaoua and site engineers used one PT878 portable flow meter at threedifferent locations to measure the flows passing through the circuits. Unexpectedly,
the results showed flow rates well above estimated level but as per design, causing
the operators to focus on other parts of the plant manufacturing process.
After a thorough investigation, engineers determined that manual valves
downstream of the condensate receiver tank were the source of the problem andnecessary corrective actions were made.

The valuable information provided by using the PT878 flow meter helped thecustomer avoid a planned shutdown for three days that would have resulted ina production loss of €5,000/hour (~USD$5,500/hour) or an estimated total loss of€360,000 (~USD$400,000).
“If the issue wouldn’t have been identified and isolated, we’d have planned for a
3-day production stop and mobilized production and maintenance departments
for a plant stop. We were at 700 ton/day of production, and in optimal production
we reach up to 1,000 ton/day. A complete production stop costs €5,000/hour.”
Sofiane Khider – Automation leader at GRD LaBelleHow we did it
It was critical to use a clamp-on flow meter to determine the condensate flow
rates at different locations of the process because there are no permanent
flow meters installed there. Using Panametrics' PT878 portable ultrasonic flow
meter that could be moved to the different measurement points, the following
measurements were carried out on carbon steel pipes with a nominal diameter of
125 mm and 6 mm wall thickness and at temperatures from 105 to 120°C:
1. At the condensate tray inlet
Estimated flow rate: 10-15 m³/h
Measured flow rate: 30 m³/h
2. At the condensate tray outlet
Estimated flow rate: 5-10 m³/h
Measured flow rate: 28 m³/h
3. At the boiler feed tank
Estimated flow rate: 5-10 m³/h
Measured flow rate: 25 m³/h

Simplified sketch illustrating the flow process

It took Allaoua approximately 20 minutes to perform the measurement at eachpoint. Based on the flow rate information from the PT878 flow meter, the root
cause of the abnormal consumption of clear water used to produce steam wasestablished.
Panametrics' TransPort PT878 portable ultrasonic liquid flow meter is afield-proven instrument that performs non-intrusive flow measurement withinminutes. Its patented correlation algorithms resolve transit-time signals inultrapure to extremely dirty liquids. Its built-in datalogger can store more than
100,000 flow data points and up to 32 sets of site location parameters.
Flow measurements atcondensate inlet and outlet

Panametrics, a Baker Hughes business, provides solutions in thetoughest applications and environments for moisture, oxygen, liquidand gas flow measurement.
Experts in flare management, Panametrics technology also reduces flareemissions and optimizes performance.
With a reach that extends across the globe, Panametrics’ criticalmeasurement solutions and flare emissions management are enablingcustomers to drive efficiency and achieve carbon reduction targets acrosscritical industries including: Oil & Gas; Energy; Healthcare; Water andWastewater; Chemical Processing; Food & Beverage and many others.
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BHCS39453 (08/2023)

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