REFINING INDIA 2025

refining india 2025

Reliable measurement in extreme refinery conditions with gamma/radiometry technology

Arun Iyer ENDRESS+HAUSER

ing, the FMG50 enables operators to visual- ise interface layers and improve separation efficiency, leading to reduced chemical usage and better downstream performance. Advantages for the user: Reduced chemi- cal consumption, optimised separation and protection of downstream equipment, while lowering CO₂ emissions through reduced energy and chemical usage. Safety, Compliance, and Operational Efficiency The FMG50 is designed with safety and operational continuity in mind: • Two-wire loop-powered detector that reduces engineering and installation efforts. • Designed according to IEC 61508 with SIL2/3 approval for all measuring tasks. • Reduced verification effort and mini- mised plant shutdowns due to state-of-the- art Heartbeat Technology. • Reduction in operating costs thanks to the high-temperature sensor that leads to water savings of up to 10 million litres per year. These features make it a reliable partner for long-term operation in the most demand- ing refinery environments. Proven in the Field Refineries across the globe are adopting the FMG50 to address measurement chal- lenges in units where traditional technolo- gies fall short. The feedback is consistent: stable measurement, simplified integration, and enhanced safety. Conclusion: A Practical Solution for Complex Measurement Needs In refining, where process conditions are often beyond the limits of conventional instrumentation, radiometry provides a sta- ble and reliable alternative. The Gammapilot FMG50, with its unique two-wire loop-pow- ered design and robust performance, offers a practical and proven solution for critical measurement tasks. Endress+Hauser is committed to supporting the refining indus- try with technologies that deliver confi- dence, safety, and long-term value, even in the most challenging environments.

In the refining industry, where process conditions are often extreme and unpre- dictable, achieving stable and accurate measurement is a constant challenge. High temperatures, pressures, corrosive media, and complex multiphase flows often render conventional measurement technologies ineffective or unreliable. In such environ- ments, radiometric transmitters emerge as a dependable alternative, offering non-inva- sive, drift-free measurement where other technologies simply cannot operate. In addition, the refineries are facing a bal- ancing act: on one hand, they must oper- ate their plants sustainably, reduce CO₂ emissions, and use energy efficiently. On the other hand, they must remain econom- ical and achieve maximum yield from raw materials that are increasingly difficult to process. Loop-Powered Simplicity with High Performance Endress+Hauser has the Gammapilot FMG50, a gamma/radiometry- based level and density detector designed to meet these challenges. This two-wire loop- powered radiometric detector is designed to be as easy to install and commission as a standard pressure transmitter. Its loop- powered architecture eliminates the need for separate power supplies or complex wir- ing, making it ideal for both greenfield and brownfield installations. This simplicity does not come at the cost of performance. The device is SIL2/3 certified, equipped with Heartbeat Technology for continuous diag- nostics, and offers smart sensor capabilities for predictive maintenance. It also offers a high-temperature variant that eliminates the need for cooling infra- structure such as air or water cooling. This combination of ease of use and high reliabil- ity makes it the preferred choice for critical applications in refining, where safety, plant availability, and measurement accuracy are non-negotiable. developed Key Applications in Refining Delayed Coker Units (DCU): Reliable level measurement under extreme conditions Coke drums present one of the most chal- lenging environments for level measure- ment, where hot steam phases, coke

build-up, and challenging process condi- tions make conventional level measurement impossible. Traditional technologies, such as radar and differential pressure, often struggle to provide consistent and safe level detection. With neutron-based backscatter solutions no longer available in the market, radiome- try is now the only viable technology for reli- able level measurement in DCUs. Advantages for the user: The FMG50, mounted externally, delivers stable and accurate reading without being affected by internal process dynamics. This helps oper- ators avoid overfill, optimise cycle times, and maintain safe operations. Fluid Catalytic Cracking Units (FCCU): Catalyst management without compromise FCCUs involve dense catalyst flows at high temperatures that are aggressive and diffi- cult to measure. Measuring catalyst levels and densities is essential for process con- trol and efficiency. Advantages for the user: The FMG50 provides non-contact, drift-free meas- urement of catalyst levels, ensuring long- term reliability and safety without process interruption.

switching up to one second, allowing for on- time process control and best-in-class sen- sitivity, which enables the reuse of older installed radioactive sources. that you can plan the source exchange well in advance Did you know? The Gammapilot FMG50‘S Heartbeat Technology allows you to predict expected remaining radioactive source operating time so

Hydrocrackers: Density monitoring in reactors at risk of explosion

Hydrocracking units operate under some of the most severe and hazardous condi- tions in refining. In the hydrocracking reac- tor, where highly explosive and exothermic reactions occur, the ebullated slurry column presents a unique measurement challenge. The FMG50 – when used with radioactive sources mounted internally to the reac- tor within a dip tube and multiple detectors mounted externally along the reactor wall – provides a reliable density profile and level measurement. This setup ensures safe, continuous monitoring without any pro- cess interruption, even in such a volatile environment. Advantages for the user: The lack of cool- ing infrastructure that otherwise mandates pumping of water or cool air up to a height of 30m brings significant Capex and Opex savings for the user. Desalters – Density Profiling: Optimising phase separation Desalters separate water and salts from crude oil. Understanding the emulsion layer is key to optimising chemical dosing and separation. With multi-point density profil-

Continuous Catalytic Reforming (CCR): Precise catalyst bed detection

In CCR units, catalysts tend to form a cone- shaped bed, making level detection par- ticularly challenging. A carefully calibrated radiometry setup is essential to accurately detect the top of the cone, which serves as the true reference point for level con- trol. Accurate point-level measurement here leads to better catalyst management, reduced losses, and improved hydrogen uti- lisation, ultimately contributing to energy efficiency and product consistency. With several years of experience work- ing with units licensed by industry majors like Honeywell and Axens, Endress+Hauser understands the nuances of CCR opera- tions. This deep process knowledge, com- bined with the capabilities of the FMG50, makes us a reliable and knowledgeable part- ner for CCR measurement solutions. Advantages for the user: Reaction time for

Contact: gamma.ehlp@endress.com

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