Products Solutions Services. Overfill Prevention. Protection against spillage to avoid cleaning cost. Slide 1 10/07/2016

Transcription

1 Products Solutions Services Overfill Prevention Protection against spillage to avoid cleaning cost Slide 1

2 Overfill Prevention The right measuring principle Point level detection Continuous measurement Interface measurement Density and concentration measurement Liquids Vibronic Conductive Capacitance Float switch Radiometric Level radar Guided level radar Ultrasonic Hydrostatic Capacitance Radiometric Guided level radar Capacitance Radiometric Vibronic Coriolis Radiometric Bulk solids Vibronic Capacitance Paddle switch Microwave barrier Radiometric Guided level radar Level radar Ultrasonic Electromechanical Radiometric Vibronic (solids in water) Radiometric Slide 2

3 Overfill Prevention Types of Installation Top mounting - for monitoring maximum level Bottom mounting - for monitoring minimum level Side mounting - for monitoring max and min level Pipe mounting - protecting pumps from running dry Slide 3

4 Overfill Prevention A solution for every application Endress+Hauser has sold more than 4.5 million Liquiphants and has generated a name for universal, reliable and safe point level switch Independent of media properties and changing/ different media Build-up Suspension Air bubbles Foam Viscosity Dielectric permittivity Conductivity External vibration Pressure and temperature changes Turbulences RELIABILITY Maintenance free due to no moving parts, corrosion resistance and highly tolerant against build up. UNIVERSALITY Unaffected by medium properties, mounting position, process pressure and temperature. Slide 4

5 Overfill Prevention Operation in different media Advantage no calibration required Preliminary products syrup, basic goods, water CIP cleaning acids, lyes highly viscous, not electrically conductive aggressive portion of solids Instrument functions independent of dielectric constant, conductivity, viscosity, density, temperature, turbulences Slide 5

6 Overfill Prevention Broadest switch portfolio for liquid hygienic applications Value Added All standard food applications Basic Food 3-A / EHEDG / EG1935 DC PNP Food flush mounting heavy build-up plug n play DC PNP Food / Life Sciences FDA compliance PNP/Relay output electro-polished Ra<0,38 Delta ferrite <1% fulfill ASME BPE USP Cl. VI +121 C full material traceability International Ex approval Performance Slide 6

7 Overfill Prevention Variety of hygienic process connections Varivent Dairy coupling (11851) Tri-Clamp Endress+Hauser weld-in adapter with adjustable flush mount process connection Endress+Hauser weld-in adapter with flush mount process connection Slide 7

8 Products Solutions Services Point level measurement accessories To meet hygienic design Slide 8

9 Proven-in-use build-up compensation Liquipoint FTW33 Very good build-up compensation over the entire application range, no product specific adjustments needed! Slide 9 R.Knall / MVA

10 Liquipoint FTW33 measuring principle Conductive & Capacitive Reliability & User friendliness! Liquipoint FTW33 uses a combined measuring principle. The sensor can compensate build-up, even non-conductive up to certain limits Guard ring Electrodes 316L with PEEK isolation Slide 10 R.Knall / MVA

11 Liquipoint FTW33 measuring range Slide 11 R.Knall / MVA

12 Liquipoint FTW33 - demonstration Slide 12 R.Knall / MVA

13 Overfill Prevention Point level detection in a filling plant Application Pipe monitoring in a filling plant Industry: Food Media: Soft drink concentrate Requirements Tight installation conditions Low immersion depth (switch point) Short response time <500ms CIP and SIP cleanable Solution Liquiphant T FTL20H (FTL33) with Varivent process connection and polished surface Ra 1.5μm Slide 13

14 Overfill Prevention Point level detection in a fermentation tank Application Lower point level detection at the tank outlet Industry: Food Media: Beer Requirements Point level switch to drain the tank completely Unaffected by foam Changing media CIP cleanable Solution Liquiphant M FTL50H in hygiene design and polished surface Ra 0.3μm. Visual function test from outside by transparent cap. Slide 14

15 Overfill Prevention Point level detection in Yoghurt Application Lower point level detection Industry: Food Medium: Yoghurt Requirement Lower limit detection unaffected by foam Turbulent medium surface caused by an agitator Solution Liquiphant M FTL50H in hygienic design Slide 15

16 Overfill Prevention Point level detection in the flavor vessel Application Industry: Food Medium: Flovouring Requirement External cleaning Hygienic design Temperature 75 C (167 F) Solution Liquiphant M FTL50H with stainless steel housing and IP 68 connection for lower limit detection Slide 16

17 Overfill Prevention Evaporator process control Process Milk in the evaporator Application Pressure, Temperature, Switch Medium Milk Location China Slide 17

18 Overfill Prevention Limit detection in 50% sodium hydroxide Application Industry: Food Medium: 50% sodium hydroxide Requirement Measurement independent of build-up Self-monitoring No moving parts in the container Solution Liquiphant M FTL51H for top level detection Slide 18

19 Overfill Prevention Point level in caustic soda storage tank Application Minimum and maximum point level detection Industry: Food (winery) Media: Caustic soda Requirements Concentrated caustic soda used for the cleaning process Resistant device for corrosive medium Reliable point level switch Application Liquiphant T FTL20 (FTL31) Slide 19

20 Overfill Prevention Point level detection for the beverage production Application Lower and top point level detection Industry: Food Media: Soft drink concentrate Requirements Unaffected by foam Price-attractive solution Vacuum-tight Application Liquiphant T FTL33 Slide 20

21 Overfill Prevention Limit detection for solid applications Soliswitch FTE30 Emitter FQR56 Nivector FTC968 Receiver FDR56 Minicap FTC260 Solicap FTI77 Soliphant FTM5x Soliphant FTM20 Slide 21

22 Overfill Prevention Guidelines on installation Right Wrong Installation from the side with 10 to 30 angle No installation in the infeed On high load, install protective roof Direct the fork right No deeper process connections than 60mm No installation restrictions Slide 22

23 Overfill Prevention Solid properties External vibration Electric properties Dielectric constant Change in weight Change in grain size Mixture of different media Pressure and temperature change Moisture content of bulk solids Changing media Flow properties in bulk solids Build-up formation Dust Slide 23

24 Overfill Prevention Filling nozzles Soliphant M Separate housing / separate instrumentation A separate housing is required if the standard housing does not have enough space in the application or if the temperatures outside the tank are so high that the electronics might be damaged. The electronic insert is in a housing which is connected to the sensor by a cable. Slide 24

25 Overfill Prevention Flour loading Slide 25

26 Overfill Prevention Soliwave M FXR 50 blockage detection and prevention of damage Slide 26

27 Overfill Prevention Solid limit switch FTM 50 Soliphant, tuning fork To ensure that a silo is really empty before you refill it with new material, but also to prevent overfilling a tuning fork is the right technology. Slide 27

28 Overfill Prevention Wheat in process silo No blocking Application Wheat (dry stored 600g/l) in process silo Temperature 15 to 40 C Control several times an hour the filling and drain Demands Abrasion, installed in flow Fast switching necessary Media that generates blocking Solution Soliphant M FTM51 works well, no blocking Slide 28

29 Overfill Prevention Wheat flour in storage silo No blocking by build-up Application Wheat flour (500g/l partly fluidized) in 12m high storage silo Temperature 15 to 40 C Overfill prevention Demands Media forms build-up High pull forces Solution Soliphant M FTM52 works well, no blocking, less than 2mm build-up due to self-cleaning effect Slide 29

30 Overfill Prevention Detect flow interruption at conveyor belt The FTR20 monitors the continuous mass flow at a transition point, a solid flow interruption is detected and signalized by the appropriate signal output. Slide 30

31 Overfill Prevention Monitoring of delivery through pipelines Function: controlling if material (flour: fine grain < 1 mm) is available behind the rotary feeder or not Solution: control and shut down of compressor and rotary feeder M Slide 31

32 Overfill Prevention Any questions? Slide 32

33 Products Solutions Services Steam & Compressed Air Slide 33

34 Utilities - W.A.G.E.S Labor Emissions/ Effluents Raw Materials Products Water Air Gas Electricity Steam Energy 35% Labour 10% Capital 20% Raw Materials 35% Slide 34

35 Products Solutions Services Steam Slide 35

36 Where is steam used? Sterilization, bottle cleaning Heating Textiles ironing, air condition Cooking (e.g. soups) Slide 36

37 Seou Energy Wei Monitoring and Utilities Handling Steam costs Slide 37

38 Steam system design at a glance Fig: Closed Steam System 1. Boiler House 3. End Use 2. Distribution 4. Condensate -> Feedwater Slide 38

39 Steam system in a glance Boiler efficiency (%) =... Slide 39

40 Steam Mass Flow Measurement Vortex or DP Flow- Volumetric Flowmeter Volume change when pressure or temperature change Vortex - Prowirl 200 with built-in temperature sensor (Pt1000)and flow computer with steam table (IAPWS-IF 97) + pressure input DP Flow + pressure sensor + temperature sensor + flow computer with steam table (IAPWS-IF 97) Slide 40

41 Steam Delta Heat: External Temperature read in Steam [MJ/h] Condensate T Slide 41

42 Is it always dry saturated steam? To achieve dry saturated steam (100% steam quality) at all times is close to impossible!!! Think of these scenarios: If heat loss along steam distribution line due to poor insulation, dry saturated steam will falls into wet steam area. Pressure change after pressure reducing valve, dry saturated steam further heat to superheated steam area Slide 42

43 Prowirl F200 Wet Steam Measurement 100% Steam Quality 90% Steam Quality 80% Steam Quality Slide 43

44 Heat loss leading to condensation and water hammer (Graphics courtesy TLV Euro-Engineering GmbH) Slide 44

45 The Dryness Fraction of Steam (x) Wet steam will cause: Lower efficiency Higher fuel consumption Might affect product quality Slide 45

46 Wet steam detection for Safety Measurement Detect malfunction of mechanical steam traps Detect leakage/ repair insulation Avoid water hammer which will cause damage on piping, valve, etc. Steam Traps: Bimetal Disc Inverted Bucket Free Float Slide 46

47 Steam Boiler What s blowdown? Feed water is treated with chemicals to adjust the PH and soften it in order to avoid corrosion and scaling. The chemicals do not boil off and concentrate in the water in form of Suspended solids: Creating sludge at the bottom of the boiler which will inhibit heat transfer and overheating of fire tubes. Dissolved solids: Leads to generation of foam (+particles) which is carried over (wet steam) and furthermore can damage equipment (valve, heat exchanger). The dissolved solids are quantified in Total dissolved solids (TDS) Boiler water blowdown is required to avoid concentration of chemicals. 2 types of blow down are essential for a proper boiler - Bottom blowdown (every 8h, 4s open valve) - TDS blowdown (continuously, typically 4-8 % of steam flow rate) Slide 47

48 Common causes of boiler / turbine downtime Oxygen pitting Corrosion Scaling Sludge ~0.1 cm of deposits 5 12% increase in fuel consumption, overheating and corrosion. Replacement/retrofitting costs $$$$ unscheduled downtime and increase in OPEX. 1. Providing good quality demineralized water. 2. Monitoring its parameter limits inline. 3. Monitoring of chemical dosing. Slide 48 To reduce: Corrosion of feed, boiler & steam systems. Scale, sludge and deposits on heat transfer surfaces. Deposition and corrosion of

49 Which analytical parameters should you measure? ph (should be in feedwater and in boiler to reduce corrosion and foaming) Conductivity/TDS/hardness (boiler feedwater and boiler water, reduce foaming) Dissolved oxygen (reduce corrosion) Silica (automated regeneration of base softener) Dissolved oxygen COS 22D ph CPS 11D Conductivity CLS 15D Liquiline transmitter (up to 4 parameters) Slide 49

50 Fault tree: water side hazards in steam Slide 50

51 Shell Fire Tube Boiler Most common boiler for process heating (saturated steam). Dennis A. Snow: Plant Engineer s Handbook Slide 51

52 The firetubes may never fall dry! This is the control band for level! Slide 52

53 Use Liquiphant and/or Levelflex! Slide 53

54 Foam inside a boiler which Level device to use? Capacitance probe: fooled by foam! DP: OK Guided radar: OK Keep in mind: Foam may lead to shut-down! Slide 54

55 Continuous Level in boilers: Levelflex M vs. DP Level Levelflex Differential pressure P (bar) in the container ρ 2??? Result of the DP measurement: An incorrect and reduced level is shown, because the transmitter does not take the fluctuating densities into account (ρ1 ρ2) AND: Lower DP measurement is subject to clogging because of sludge! ρ 1 P (bar) = h x ρ x g Density: ρ 1 > ρ 2 Result of level measurement with Levelflex The correct level is shown because Levelflex works independently of density fluctuations while measuring precisely up to the liquid surface Slide 55

56 Wet Leg dp Level Measurement Slide 56

57 Density of Water / Resulting Errors -> GPC *Gas Phase Compensation Slide 57

58 Measuring in a bypass is better! Level forms a hill toward the outlet of the boiler through the crown valve This will fool level measurements inside the boiler! -> use bypass! Slide 58

59 Seou Energy Wei Monitoring and Utilities Handling Potential - Optimizing of Boilers Technique/Methode Saving potential Improved operation and maintenance of boilers Up to 5% Improved water treatment and boiler water conditioning Up to 2% Total dissolved solids (TDS) control and boiler blowdown Up to 2% Blowdown heat recovery Up to 6 % Boiler and burner management systems, digital Up to 4 % combustion controls and oxygen trim Variable speed drives (VSDs) for combustion air fans Up to 1% Flue gas shut-off dampers Up to 1% Economisers Up to 5% Combustion air preheating Up to 2% Slide 59

60 Economizers can improve efficiency by up to 5% Condensate return Feed water Make-up water Steam Nat gas Flue gas Air Blowdown Slide 60

61 Example: Flue gas energy recovery Example: Steam Boiler, nominal load 8 t/h generates about 9,700 Nm³/h flue gas. By recovering about l fuel per 10 C temperature reduction can be saved. Slide 61

62 Insulate piping Heat loss every 30m of steam pipe without isolation ( /year)* Pipe size (DN) Steam pressure (bar) U.S. DOE: Steam System Opportunity Assessment; 2002 Slide 62

63 Leakage - Visible steam loss Steam leaks have got one advantage: in case steam is leaking, you will immediately see it. Energy Efficiency Manual; Wulfinghoff, Energy Institute Press, 1999 Slide 63

64 Avoid leakage Steam pressure Hole diameter Steam loss kg/h Annual loss in * 7.9 bar 0.16 cm bar 0.32 cm bar 0.64 cm bar 1.27 cm bar 2.54 cm bar 0.16 cm bar 0.32 cm bar 0.64 cm bar 1.27 cm bar 2.54 cm Canadian Industry Programme for Energy Conservation: Energy Efficiency and Management Guide; 2002 Slide 64

65 Seou Energy Wei Monitoring and Utilities Handling Check list - Optimizing of Boilers Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Establish steam needs Design piping, fittings and condensate recovery Select fuel type Select boiler type Check and monitor the excess air. Check the distribution of the fuel on the bed in sold fuel combustion systems. Check the flame patterns in a liquid or gaseous fuel combustion system. What opportunities exist to change the fuel type to one with more efficient combustion or lower carbon intensity? Is there an opportunity to fit an economizer? What combustion air pre-heat could be used? Check for insulation damage and air leaks. Ensure the heat transfer surface are clean, or can be cleaned easily and often. Slide 65 Review boiler set points to minimize short cycling. Plan for efficiency Select control and monitoring systems

66 Seou Energy Wei Monitoring and Utilities Handling Checklist Optimizing of distribution system Ensure distribution system is rationalized and all dead legs removed. Ensure distribution system pipe sizes are appropriate for the demand. Remove throttling valves and make use of VSDs on all pumping systems. Repair leaks. Insulate the distribution system. Re-route any hot piping that may be passing through chilled or air conditioned spaces. Slide 66

67 Products Solutions Services 2. Compressed Air Applications Slide 67

68 Applications in Food & Beverage Industry Compressed air is used as a power source for many food and beverage operations as it is a versatile, safe and flexible way to transmit energy. Typical processes where compressed air is needed: Product handling - Product transport at high speed within the production process Filling systems - for food or bottles Liquid pumps - transport of liquid products in the production and filling process Processing - cutting and peeling of products such as fruits and vegetables Packaging Packaging processes Instrumentation air is very often used for pneumatic control of pilot valves for process valves Slide 68

69 Typical Lifetime Compressed Air Costs 76% 12% 12% Equipment & Installation Maintenanc e Electricity *Assumptions in this example include a 75hp compressor operated 2 shifts a day, 5 days a week at an aggregate electric rate $0.05/kWh over 10 years of equipment life Slide 69

70 Typical design of compressed air systems Slide 70

71 Flow metering in distribution systems In compressed air system the distribution network acts as air storage. The air flows from points of high pressure to points of lower pressure. Thus the flow direction in a distribution network is bidirectional. Flow P P P Always measure flow in branch line not in the ring main! For proper balancing of air distribution install the flow meters next to the consumers or if necessary use a bidirectional flow meter Slide 71

72 Detecting leaks balancing method By balancing of air production and consumption leakage can be detected in time. The leakage rate is expressed as percentage of produced air. % Air Consumed Leakage can be indicated by alarm. In this way apart from typical leakage it s also possible to detect sudden or uncommon leakage, e.g. due to disruption. Air Produced Slide 72

73 Leakage measurement using t-mass 150 Switch off all consumers (pressurized system!) e.g. during weekend and leave compressor running. If the thermal meter is still reading flow this will indicate the amount of leakage! Slide 73

74 Compressed Air: Volume or Corrected Volume? Suction/ Free Air Delivered Compressor Counter 1 Counter 2 Consumption Volume 10 m 3 /min 1.50 m 3 /min 1.46 m 3 /min Temperature 20 C 35 C 20 C Pressure 1 bar a 7 bar a 6.8 bar a Density 1.2 kg /m kg /m3 8.1 kg /m3 Slide 74 Corr. Volume (0 C; bar a) Volume 9.19 Nm³/min changes as a 9.19 function Nm³/min of p/t, 9.19 Nm³/min corrected volume is constant!

75 Corrected Volume Nm 3 or Sm 3?? Normal cubic meter (Nm 3 ) and Standard cubic meter (Sm 3 ) both are corrected volume term Corrected volume is NOT a volume term, but a mass term They refer to the same reference pressure but to different reference temperatures 1 Nm 3 1 Sm 3 Examples: Examples: 1m P=1013mbar T= 0ºC Air = kg Hydrogen= kg Chlorine= kg 1m P=14.696psiT= 70ºF Air = kg Hydrogen= kg Chlorine= kg 1m Deviation 6-8%!!!! 1m Slide 75

76 Free Air Delivery and Common Mistake The amount of air the compressor sucked in during a test at reference conditions (1 bar a and 20 C according to ISO 1217). Slide 76 Wrong flowrate information wrong sizing l/s uses DN80 (3 ) flowmeter while 15 7 l/s uses

77 Detected Leakage at PC-F: ~13% Losses! Consumption of compressed air at Flowtec on a beautiful sunny Friday Slide 77

78 Detected Leakage at PC-F: ~13% Losses! Slide 78 Consumption decreases before weekend and about at 9 p.m. production stops

79 Detected Leakage at PC-F: ~13% Losses! although there is no production consumption at Saturday still about 100 kg/h?? Slide 79

80 Detecting Leakage at PC-F: ~13% Losses! as well on Sunday Slide 80

81 Detecting Leakage at PC-F: ~13% Losses! Mean consumption production starts on Monday morning at 5 a.m.. Slide 81

82 Leakage cost of compressed air Hole diameter [mm] air barg [Nl/s] cost per year in EUR/kWh Slide 82

83 Compressed Air Leakage (photograph: courtesy B.E.S.T. Fluidtechnik Swagelok) Slide 83

84 Filter Supervision to avoid pressure/energy losses Slide 84

85 Compressed Air KPI Compressed Air Production vs. Electricity SEC ElectricityConsumption Air Pr oduction Nm 3 kwh Slide 85

86 SEC Specific Energy consumption Source: Specific power consumption compressed air, Frauenhofer 2003 Slide 86

87 Efficiency and Thermal Waste Heat Energy Flow in a typical Screw Compressor. The Carbon Trust Good Practice Guide 238: Heat Recovery from Compressors Slide 87

88 Options for Heat Recovery Usage Water heating Space heating Standard dryer regeneration Compressed air treatment Building services Options for using recovered heat from air compressors Process drying Integral compressor dryers Boiler preheating Heating Feed water Combustion air Slide 88

89 Potential Savings in Compressed Air Saving Potentials Investment ³ Management Actions Raise the awareness of all users to the proper use of compressed 10-15% Low air Develop and implement a maintenance Programme for the whole 5-8% Low system Install Metering and implement monitoring 5-10% Medium Use only trained and competent personnel for installation, 5-10% Low servicing and system upgrades Develop and implement a purchasing policy 3-5% Low Technical Actions Implement a leak reporting and repair Programme 20-40% Low Do not pressurize the system during non-productive periods 2-10% Low Fit dryer controls (refrigerant and desiccant) 5-20% Medium Install compressor drive and system control measures 5-15% Medium Source: The Carbon Trust (2005): GPG385 Energy Efficient Compressed Air Systems, London. Install heat recovery measures where appropriate Up to 75% Medium Slide 89

90 Start measuring! Slide 90

91 Picomag smart plug-and-play flowmeter for utilities Coming Soon: 1 Nov Flow and temperature measurement up to 70ºC (Size: DN15-50) 2. Easy commissioning and operation via SmartBlue App 3. Large and freely configurable display (flowrate, temperature or totalizer) 4. Different adapters can be ordered (eg. Tri-clamp) 5. 2 free configurable outputs/ inputs includes IO-Link (optional output/ input: current, pulse, voltage or switch) 6. IO Link seamless integration into established fieldbus system and easy remote configuration of the device in the control room Slide 91

92 Configuration and communication with IO-Link Engineering Operation Asset Mgmt. Ethernet Via Bluetooth wireless technology Wireless remote access via SmartBlue App Available for Android and ios Full menu access of the device Via IO-Link IO-Link point-to-point connection Complete remote configuration of the device in the control room Full menu access of the device System integration via IODD Slide 92 Flowtec Marketing / HRO

93 Products Solutions Services Thank you for your attention! Any Questions? Slide 93