Table of Contents
ONE Series Transmitter Enhances Safety and Reliability in a European Biogas Plant
Introduction
Biogas plants play a vital role in converting organic waste materials such as manure, sludge, and industrial waste into renewable energy.
However, maintaining safe operating conditions inside digesters is critical for ensuring plant efficiency, equipment protection, and personnel safety.
A leading European biogas company faced several challenges related to pressure monitoring and compressor protection within its facility.
The company required a reliable, easy-to-use, and safety-certified solution that could continuously monitor digester pressure and automatically activate backup systems when necessary.
To overcome these challenges, the company selected the ONE Series Transmitter from United Electric Controls, providing a complete pressure monitoring and safety solution.
The Challenge
The biogas facility operated multiple digesters where organic materials decomposed and generated biogas, primarily consisting of methane. As gas accumulated within the digesters, pressure was exerted on the seal hatches and associated equipment.
The customer needed a dependable system to:
- Monitor pressure on each digester seal hatch.
- Continuously supervise the pressure in the main compressed air line.
- Protect the primary air compressor from unexpected failures.
- Automatically activate a backup compressor if the main compressor stopped operating.
- Meet strict safety requirements using ATEX and SIL-approved instrumentation.
In addition to these technical challenges, the customer was dissatisfied with its existing instrumentation supplier due to high operating costs, poor service support, and limited functionality.
The company needed a modern solution that would simplify operations while improving plant safety and reliability.
The Solution
After evaluating available options, the customer selected the ONE Series Transmitter from United Electric Controls with a measuring range of 20 bar.
The transmitters were installed on each digester and along the main compressed air line to provide continuous pressure monitoring and control.
The solution immediately addressed the customer’s operational and safety concerns while offering several additional benefits.
Key Benefits of the ONE Series Transmitter
1. Multiple Outputs Integrated into a Single Device
One of the most significant advantages of the ONE Series Transmitter is its ability to combine several functions into one compact instrument.
When the main air compressor experiences a failure:
- The transmitter’s safety relay trips within 100 milliseconds.
- The backup air compressor is automatically activated.
- A discrete output simultaneously sends a signal to the PLC.
- The PLC can then trigger alarms, notifications, or additional corrective actions.
This integrated functionality eliminates the need for multiple standalone devices, reducing installation complexity and overall project costs.
2. Fast Response for Critical Safety Applications
In industrial environments, response time can be the difference between normal operation and costly downtime.
The ONE Series Transmitter provides rapid relay switching, ensuring immediate response during compressor failures or abnormal pressure conditions.
This fast action helps maintain continuous plant operation while protecting critical equipment from damage.
3. Easy-to-Read LCD Display
Plant operators appreciated the large LCD display integrated into the transmitter.
The display allows personnel to:
- View real-time process pressure.
- Monitor operating conditions locally.
- Verify system status without additional equipment.
This improves operator awareness and simplifies routine inspections.
4. User-Friendly Local Programming
Another major advantage is the ability to configure the device directly from the keypad.
Operators can easily:
- Adjust setpoints.
- Configure deadbands.
- Modify operating parameters.
- Fine-tune system performance.
Deadbands can be programmed up to 100% of the measurement range, providing exceptional flexibility for various process requirements.
This local programming capability reduces commissioning time and minimizes maintenance efforts.
5. ATEX and SIL Certified Safety
Safety was a critical requirement for the biogas plant due to the presence of methane and potentially hazardous operating conditions.
The ONE Series Transmitter met all project requirements through:
- ATEX approval for hazardous areas.
- SIL2 and SIL3 capability.
- Independent third-party exida SIL certification.
These certifications provided the customer with confidence that the system would operate reliably in safety-critical applications.
Results Achieved
Following installation, the customer experienced several measurable improvements:
- Improved monitoring of digester seal integrity.
- Reliable pressure supervision throughout the compressed air system.
- Automatic backup compressor activation during primary compressor failure.
- Reduced downtime risk.
- Simplified operation and maintenance.
- Lower overall system complexity through integrated functionality.
- Full compliance with plant safety requirements.
- Improved confidence in the reliability of critical pressure monitoring systems.
Why the ONE Series Transmitter Is Ideal for Biogas Applications
Biogas facilities require instrumentation that can withstand demanding environments while maintaining high levels of safety and reliability.
The ONE Series Transmitter is particularly suitable because it combines:
- Pressure measurement
- Safety switching
- Relay outputs
- PLC communication
- Local programming
- Hazardous area approvals
All these features are integrated into a single device, making it an efficient and cost-effective solution for biogas plants, wastewater facilities, chemical plants, and other industrial applications.
Looking for ONE Series Transmitter Suppliers?
SWME Control Systems Trading LLC is one of the trusted ONE Series Transmitter suppliers serving industrial customers across the Middle East.
As experienced ONE Series Transmitter suppliers in UAE, we provide technical support, application assistance, and complete instrumentation solutions for biogas, oil & gas, water treatment, power generation, and process industries.
Contact our team for product selection and application support.
Visit: Official Website
Email: dubai@swme.in
