Protecting Petrochemical Operations: Nexisense Explosion-Proof Pressure Transmitter in the Natural Gas Sector

Guarding Petrochemical Operations: Nexisense Explosion-Proof Pressure Transmitters in Natural Gas

The petrochemical industry is like a grand symphony, where each pressure measurement in the process pipelines—from raw material cracking to product refining—is a critical note. In high-temperature, high-pressure, and chemically complex environments, stable and reliable pressure measurement directly affects plant efficiency and safety. Nexisense flameproof explosion-proof pressure transmitters provide professional performance, becoming a trusted partner in precisely monitoring the "petrochemical dragon." They meet strict safety requirements while delivering continuous accurate data under harsh conditions, helping companies achieve operational goals of safety, stability, longevity, full capacity, and optimization.

Pressure Monitoring Challenges in Petrochemical and Natural Gas Sectors

In petrochemical plants with towers and pipelines everywhere—especially during natural gas processing, liquefaction, and transmission—the risk of explosion is omnipresent. Flammable gases like hydrogen, methane, and benzene fill pipelines, and any ignition source can lead to catastrophic consequences. Additionally, processes involve highly corrosive fluids and rapid temperature changes, accelerating conventional instrument failure, causing measurement drift or device damage.

Nexisense explosion-proof pressure transmitters are designed to address these issues, combining a diffused silicon core with a robust flameproof housing. They support 4–20 mA output or HART protocol for easy integration into DCS systems. Whether monitoring upstream natural gas wellhead pressure or controlling downstream refinery reactors, they provide real-time, accurate pressure signals, enabling engineers to adjust parameters promptly and avoid overpressure or underpressure risks.

Explosion-Proof Certification: Access to Hazardous Zones

Safety is the lifeline of petrochemical operations. Equipment in hazardous areas (Zone 1 or Zone 0) faces the highest standards. Nexisense explosion-proof pressure transmitters are Exd IIC T6 Gb certified, meaning the housing can contain internal explosions without transmitting them externally, even in the most severe IIC gas environments such as hydrogen. Thick aluminum or stainless steel enclosures and specialized seals ensure intrinsic safety.

At natural gas compression stations or LNG storage sites, this certification allows the device to legally “reside” in core areas. Compared with intrinsically safe (Exi) types, flameproof devices are better suited for high-power applications and easier to maintain. Users report that deploying Nexisense products significantly improves safety audit compliance and reduces production downtime caused by non-compliant instruments.

Corrosion Resistance: A Shield Against Complex Media

Petrochemical media often contain acids, alkalis, sulfides, or chlorides, which can corrode conventional sensor diaphragms, causing leaks or failure. Nexisense explosion-proof pressure transmitters offer optional Hastelloy C, tantalum, or 316L stainless steel diaphragms, performing excellently in highly corrosive environments and resisting H2S, HCl, and similar compounds.

For example, in natural gas desulfurization units, sulfur-containing gases pose severe challenges. The fully welded structure of Nexisense products prevents media intrusion into the electronics cavity, ensuring long-term sealing. This extends equipment life and reduces environmental pollution risks, meeting increasingly stringent environmental regulations.

Temperature Compensation: Accuracy Across a Wide Range

From northern winters to southern summers, outdoor petrochemical equipment temperatures can range from -40°C to over 80°C. Temperature fluctuations cause sensor zero drift and sensitivity changes, affecting measurement reliability. Nexisense built-in digital temperature compensation modules correct errors in real-time, maintaining accuracy within 0.25% FS across the full temperature range.

This feature is particularly useful in long-distance natural gas pipelines. Variable environmental conditions along the route require pressure data for flow calculation and leak detection. Accurate compensation enables the system to capture subtle variations and support predictive maintenance. In practical projects, incorporating these transmitters improves process control stability and reduces energy consumption.

Typical Applications in the Natural Gas Sector

The natural gas value chain—from extraction and purification to transmission and storage—relies on pressure monitoring at every stage. Nexisense explosion-proof pressure transmitters are widely used at wellheads, compressor outlets, gas storage facilities, and LNG terminals.

At compression stations, they monitor multi-stage compression pressures to prevent equipment overload; in pipeline SCADA systems, they provide differential pressure signals for leak detection. With Modbus protocol integration, they support remote diagnostics and alarm systems. In multiple large-scale gas field projects, Nexisense instruments reduced failure rates by 30% and significantly improved operational continuity.

Additionally, in refinery cracking furnaces or hydrogenation units, high-temperature versions (supporting up to 150°C process media) ensure stable reactions and help optimize product quality.

Technical Highlights and Extensions of Nexisense Products

Nexisense explosion-proof series covers 0–100 MPa, supports gauge, absolute, and differential measurements, with flexible outputs including current, voltage, and digital signals. IP67 protection and industrial-standard vibration resistance ensure robust operation.

With digital transformation, these products can integrate wireless modules and support 5G transmission, enhancing smart petrochemical plant capabilities. From compliance to efficiency, Nexisense provides comprehensive industry support.

Case Studies

At a coastal LNG terminal previously using imported instruments with high maintenance costs, replacing them with Nexisense explosion-proof pressure transmitters resulted in three years of fault-free operation in a high salt-spray environment, with excellent data consistency, enabling unmanned monitoring.

In a northern gas field pipeline project, conventional instruments drifted under extreme cold. Introducing Nexisense temperature-compensated transmitters stabilized pressure curves, supporting accurate metering and settlement, saving tens of thousands of yuan annually in maintenance costs.

FAQ

• What does Exd IIC T6 Gb certification mean? Exd indicates flameproof type; IIC is suitable for the most hazardous gas group (e.g., hydrogen); T6 indicates surface temperature not exceeding 85°C; Gb indicates equipment protection suitable for Zone 1.

• How to select diaphragm material? Based on media corrosiveness: standard 316L for general acids/alkalis; Hastelloy C for strong corrosion such as H2S; tantalum for fluoride environments.

• What communication options are supported? Standard 4–20 mA analog output, optional HART or Modbus RTU, suitable for integration with PLC/SCADA.

• How to use in high-temperature media? Choose the high-temperature version supporting up to 150°C media, combined with heat sinks to extend the range.

• Maintenance interval? Annual calibration recommended; check cables and seals. Built-in diagnostics allow remote status monitoring.

Conclusion

In the petrochemical and natural gas industries, Nexisense explosion-proof pressure transmitters, with reliable flameproof design, corrosion resistance, and intelligent compensation, safeguard every pipeline’s pressure pulse. They are not just monitoring tools but partners in enhancing plant resilience and efficiency. Choosing professional instrumentation strengthens sustainable development, keeping the "petrochemical dragon" safely on track.