Enhancing RTD Reliability for Gas Pipelines: A Case Study on Innovative Gas Measurement Solutions
Accurate gas measurement is critical for pipeline operators to ensure precise billing and operational efficiency. However, traditional Resistance Temperature Detectors (RTDs) often fall short of meeting the demanding requirements of gas pipelines. In this case study, provided by our partner United Electric Controls (UEC), we explore how innovative RTD engineering addressed common challenges, improved reliability, and ultimately increased uptime for a major pipeline operator.
The Challenge
Gas pipelines use flow computers to calculate the volume of gas delivered based on inputs such as temperature monitored by RTDs. The operator faced several issues with standard RTDs:
- Cable Stress and Wear: The original RTDs featured a PVC-jacketed cable exiting directly from the sheath. Bending the cable during installation created a wear point, leading to frequent failures.
- Moisture Intrusion: Upgrading to an armored cable resolved the bending issue, but the armor was not waterproof. This allowed moisture to penetrate the sheath and cause short circuits.
- Vibration-Induced Fatigue: The stainless steel compression fittings used to secure the RTDs were vulnerable to vibrations from pressure fluctuations and flow, leading to fatigue and eventual failure at the ferrule.
Innovative UEC RTD Design Solution
To overcome these challenges, the pipeline operator implemented several key design improvements:
- Pre-Bent 90-Degree Cable: Incorporating a pre-bent 90-degree angle in the wiring eliminated stress during installation, ensuring a smoother and more reliable setup.
- Sealed Armor Cable: The new design featured an armored cable with a PVC jacket sealed to the sheath. This innovation effectively prevented moisture from causing electrical shorts.
- Teflon® Compression Fitting: Replacing stainless steel fittings with Teflon® fittings minimized vibration-induced fatigue. This change not only improved RTD durability but also reduced lightning-related failures by enhancing overall isolation.
Results and Benefits
The upgraded UEC RTD design delivered significant advantages:
Reliable Measurement: Enhanced accuracy in temperature monitoring ensured more precise gas volume calculations and billing.
Simplified Installation: The pre-bent cable design reduced installation challenges and the potential for damage during setup.
Increased Uptime: With fewer failures, maintenance costs dropped, and revenue loss due to RTD issues was minimized.
Westech Industrial: Your Western Canada Distributor
Westech Industrial is proud to be the exclusive distributor for Western Canada. Our commitment to innovation and quality means you receive not only advanced products but also expert support tailored to your needs. We work closely with partners like UEC to bring you state-of-the-art solutions that enhance operational performance in challenging environments.
Conclusion
This case study highlights the importance of UEC's specialized RTD engineering for ensuring accurate gas measurement in pipelines. By addressing common failure points and incorporating robust design features, pipeline operators can achieve reliable performance and significant cost savings. To learn more about our innovative solutions and how we can support your operational needs, please visit our website or contact our team for a personalized consultation.