Tech days Edmonton. Next Level Instrumentation. Products Solutions Services. By Ing. Rob Vermeulen, Bec

Transcription

1 Products Solutions Services Tech days Edmonton Next Level Instrumentation By Ing. Rob Vermeulen, Bec By Gerhard Jansson, Application Support Level + Pressure at SC-CA Slide 1

2 Why do we need to go to the next level.? How do you know that what an instrument measures is ok and why is that important? So your plant becomes safer. So you have better process control, leading to improved productivity and quality. So you can predict maintenance and service activities pro-active in stead of in a constant crisis mode. Slide 2

3 Heartbeat Technology - elements Heartbeat Technology Heartbeat Monitoring Heartbeat Verification Pass / Fail Heartbeat Diagnostics Slide 3

4 Heartbeat Technology - in operation Continuous output of data influenced by process On demand confirmation of instrument functionality Heartbeat Monitoring Heartbeat Verification Pass / Fail Heartbeat Diagnostics Continuous self-diagnostic of Level, Flow and Pressure instruments Slide 4

5 Onboard diagnostics running in the background Continuous automatic internal check in the device Logic program run control Check Reference pulse HF Quartz synchronization Measuring cycle time Supply voltage Temperature Check sum RAM Cable breakage Continuous self-monitoring to check the correct functionality of the device More than 80 diagnostic measures and techniques permanently running in the background Slide 5

6 Measurement signal Verification Multi Echo Tracking Animation to describe the Multi-Echo Tracking (explained on a Micropilot) Start by click the animation Slide 6

7 Process Monitoring Process Heartbeat Monitoring. Distance Terminal voltage Electronic temperature Relative echo amplitude (Signal/noise ratio) - Build up on antenna -Foam level - Product identification (oil or water etc) We give you more than a mere measured value. Slide 7

8 Process monitoring the Heart beat of your process Animation of foam measurement (explained on a Micropilot) Start by click the animation Slide 8

9 Do I need software to monitor Heart beat? Housing Display mechanical buttons or optical buttons for operation from outside Electronics + HistoROM Plastic Alu 316L plastic Remote Display FHX50 2-wire 316L Approval ATEX 4-wire 4-20mA basic liquid liquid hygienic/corrosion resistant 4-20mA 4-20mA insulated 4-20mA PFS HT/HP 4-20mA DC basic solid 4-20mA AC solid + 100mm horn up to 250 C or 450 C + planar + 100mm horn up to 400 C FMR50 FMR51 FMR52 FMR53 FMR54 FMR56 FMR57 Slide 9

10 .. But you can. DTM start page with clear instrument health status Example for Micropilot Health status Health status F/C/S/M Clear diagnostic message + Remedy information Slide 10

11 Micropilot FMR5x SAFE PRECISE EFFICIENT EFFICIENT The Micropilot FMR5x offers a so called HistoROM data management concept function to make maintenance, diagnosis and setup of the device as easy and fast as possible Slide 11

12 HistoROM Functions HistoROM: Storage of device parameters Storage of event log book (basic: 20 events) Together with on-site display: Backup of device settings in the display Restore of device settings from display backup file Import settings from device 1 to device 2 (e.g. same tank, same installation, same settings) The HistoROM is fixed in the housing (can not be lost or forgotten ) Benefit: Easy electronic exchange No need of SW tooling or new setup to start measurement, only a screw driver is necessary History information for diagnostic purposes Safety for configuration data without a SW tooling, time saving full restore and backup Time saving setup of tank farms with import of settings from device to device Slide 12

13 Animation HistoROM Start by click the animation Slide 13

14 HistoROM Example HistoROM functionality Electronic change during night shift The HistoROM is fixed in the housing (can not be lost or forgotten ) Slide 14

15 Micropilot FMR5x Next Level Instrumentation Extended HistoROM Coming free of charge with Levelflex, Micropilot (HART SW ) Storage of Event recorder according to Endress+Hauser standard 100 events The HistoROM is fixed in the housing (can not be lost or forgotten ) Recording of trends (FIFO memory) Up to 4 independent parameters (e.g level, Temp, S/N, terminal voltage etc) Max. 500 values / 1 parameter Or 250 values (with 2 parameters),, 125 values (4) Storage of reference curve Comparison to start up / commissioning conditions for maintenance Slide 15

16 Micropilot FMR5x Next Level Instrumentation Extended HistoROM Event List up 100 events Slide 16

17 Micropilot FMR5x Next Level Instrumentation Extended HistoROM - Trend Visualization of up to 4 trend values Visualization of events in correlation with trend values Slide 17

18 Micropilot FMR5x Next Level Instrumentation Extended HistoROM - Statistics Statistical information about recorded values Slide 18

19 Micropilot FMR5x Next Level Instrumentation Diagnosis: Reference curve Button to read reference curve Reference curve: The reference curve shows a previous state of the envelope curve! It can be recorded manually under Expert>>Diagnostics>>Envelope Diagnostics. Reading the envelope curve is possible with the read reference curve button: Slide 19

20 Process monitoring the Heart beat of your process Build up on an antenna (explained on a Micropilot) Start by click the animation Slide 20

21 Products Solutions Services Proof testing. Necessary, Safe and Practical. Next Level Instrumentation Slide 24

22 Incidents Preceding Improved Safety Standards Still happening. Pernis Oil Refinery, Holland Jan 20, 1968 (2 dead, 85 injured) Flixborough, UK Jun 1, 1974 (28 dead, hundreds injured) Seveso, Italy Jul 10, 1976 (700 injured) Bhopal, India Dec 2, 1984 (2,500 dead, 100,000 injured) Piper Alpha, UK (North Sea) Jul 6, 1988 (165 dead, 61 injured) Slide 25

23 Still happening. Still happening. Firefighters fight flames at the BP plant in Texas City after the July 28, 2005 explosion. (15 dead & 170 injured) Slide 26

24 The Buncefield fire - Sunday 11 December 2005 Investigation by the HSE (Health & Safety Executive) 10 December 2005: at around 19.00, Tank 912 started receiving unleaded motor fuel from at about 550 m3/hour 11 December 2005: From approximately 03.00, the level gauge was stuck at 2/3 full Filling continued with around 550 m3/hour At tank starts overflowing Evidence shows that the protection system did not operate CCTV footage shows vapour starting to flow and at 05.46, the vapour cloud was 2 m deep and flowing out of the bund in all directions By 05.50, the vapour cloud had started flowing off site Source Buncefield rep Slide 27

25 The Buncefield fire - Sunday 11 December 2005 Investigation by the HSE (Health & Safety Executive) At 06.01, the first explosion occurred Fire, engulfs over 20 large fuel storage tanks 43 people injured in the incident Amazingly no fatalities Several Buildings damaged The fire burned for 3 days Source Buncefield reports Slide 28

26 So what can help prevent this in future? Safe Instrumented Solutions - Good Engineering is Crucial Clear Application Reliable Measuring Principle Correct Installation & Start-up Regular Smart Functional Proof Testing Slide 29

27 Fixed Roof SAFE LAHH Solutions Levelflex Guided Wave Radar, Time Domain Reflectometry Measurement of true level using dielectric reflection at phase change Liquiphant Vibronics, Tuning Fork Measurement of aggregation phase by fluid density, Gas versus Liquid Slide 30

28 Fixed roof solutions Functional Safety Proof testing Mounting Guided Wave Radar (TDR) Proven in use Suitable for SIL 2 Internal redundancy (EOP) Analogue output (4-20 ma) Comparison potential to TG system (deviation) Switching in safety system or RMA422 By expert inspection Proof test coverage depends on inspection depth Top Liquiphant IEC design Proven in use Suitable for SIL 2 / 3 (3 when used in omogeneous redundancy) Switching in remote switch unit Discrete output (relays) By expert inspection Proof test coverage depends on inspection depth Side Top adjustable Top Slide 31

29 Guided radar as over spill protection Levelflex as SIL 2 overspill protection on Fixed roof tanks and LPG bullets Slide 32

30 Products Solutions Services Example Level Continuous Guided Wave Radar Levelflex FMP 5x Start by click the animation Slide 33

31 Smart Proof Testing without removal 3 step-by-step proof test procedures are available MAX MIN Slide 34 Slide 34

32 SMART PROOF-Test Sequence C Preparation and Tools Step 1 Deactivate SIL mode. Step 2 Step 3 Connect suitable measuring device to the current output (recommended accuracy better than ±0.1 ma) Determine the safety setting: level limit or level range MAX MIN Slide 35

33 SMART PROOF-Test Sequence C Example HH e.g. at 80% Step 4 Start built-in SELFCHECK-Routine Proof test coverage, PTC = 0.93 Step 5 1. Electronic simulation of level [79% just below MAX] 2. Verification of output current [0-100% = 4-20mA] 79% 16,64mA Step 6 1. Electronic simulation of level [81% just above MAX] 2. Verification of output current [0-100% = 4-20mA] 81% 16,96mA Slide 36

34 Floating Roof Tanks Independent High Level Alarms / Radar Proof Testing external Combined Swivel plate for functional proof testing External Swivel plate for functional proof testing Slide 37

35 Secure Switch Settings using Contact Plate Slide 38

36 So what can help prevent this in future? Overfill Prevention Cabinets according to API 2350 Slide 39

37 Reports and recommendations Buncefield report Recommendations on the design and operation of fuel storage sites Major Incident Investigation Board (MIIB) Health and Safety Executive (HSE) Research Report (RR872) Identification of instrumented level detection and measurement systems used with Buncefield in-scope substances American Petroleum Institute s (API) Recommended Practice RP2350 Overfill Protection for Storage Tanks in Petroleum Facilities Slide 40 Slide 40

38 API American Petroleum Institute The fourth edition API 2350 (May 2012) is finalized by API and it combine the standards of RP 2350 with the functional safety standards of Safety Instrumented Systems (SIS) as described in IEC Tanks in fully automated operation shall be equipped with an independent LAHH (Level Alarm High High) sensor (API ) Commonly Used Types of Liquid Level Sensors Tuning fork electronic point sensor (API2350 Table C.1) Proof testing is an essential element to all components and systems including the sensor, the test need not require filling the tank above its maximum working level, the combined procedure shall ensure that all elements of the entire loop are tested within the proof test interval (API ) Automated Overfill Prevention System (AOPS) when an AOPS is required (risk analysis of owner and operator policy or regulation) option 2 for new facilities: an AOPS designed and managed in accordance with requirements of ANSI/ISA 84-1 (IEC61511 modified) shall be required (API ) Slide 41

39 Buncefield Report Slide 42

40 Products Solutions Services Example - Level switch Tuning fork switch Liquiphant FTL5x, FTL7x Liquiphant Failsafe Start by click the animation Slide 43

41 Self Diagnostics Liquiphant M/S (FEL 51 57) Continuous monitoring of vibration frequency Reliable alarm function with each electronic insert! fa -15% switch point approx. 850 Hz Immersion depth 25 mm 1 inch 0 A L A R M fa oscillation frequency in air approx. 1 khz A L A R M fa -15% fa fa + 6,5% 1500 f [Hz] sensor alarm 0,4 s delayed normal operation corrosion alarm 60 s delayed sensor Alarm 0,4 s delayed Slide 44

42 Liquiphant SIL Product Portfolio today SIL2 MIN/MAX SIL3 MAX PFM FEL51, 2-wire AC FEL52, 3-wire DC-PNP FEL54, AC/DC DPDT FEL55, 8/16 ma Liquiphant M FTL50/51/51C Liquiphant S FTL70/71 Nivotester FTL3x5 P Liquiphant S Nivotester PFM Failsafe FTL80/81/85 FTL825 Liquiphant M FTL50/51/51C Liquiphant S FTL70/71 NAMUR PFM Liquiphant M FTL50/51/51C Liquiphant S FTL70/71 Nivotester FTL325N Liquiphant M FTL50/51/51C Liquiphant S FTL70/71 Nivotester FTL3x5 P (with Redundant installation) Slide 45

43 Proof-testing Electronic FEL 51/52/54/55 Proof test procedures: wet test in application test in reference tank Test interval: 5 years x Liquiphant FTL 50/51/70/71 DCS-System Electronic inserts FEL 51(2 wire AC) FEL 52(3 wire DC) FEL 54(AC/DC+Relay) FEL 55 (8/16 ma) PTC = Proof Test Coverage Slide 46

44 Proof-testing PFM-Electronic FEL 57 + FTL 325P Wet testing in application or reference tank Test generator (push-button at signal converter Nivotester) (PTC 90 %) - Electronic insert inclusive Self diagnostics - Signal Converter Nivotester - Short circuit, - load or cable break- detection - subsequent alarm-system Test interval: wet testing 5 years (only in low density media required) push-button 1 year Liquiphant FTL 50/51/70/71 2-wire, intrinsically safe empty : 150 Hz full : 50 Hz Nivotester FTL 325 P Fault : 0 Hz Slide 47

45 Liquid Bulk Storage Independent High Level Alarms Best technology Available Tuning fork switch Liquiphant is always the first solution. Internal Floating Roofs and External Decks do require stilling wells or side mounted nozzles to be installed. Slide 48

46 Separate overfill prevention from the tank gauging system Level limit PFM DO Namur SIL 2 Level 4-20mA FTL325P RMA422 RMA422 WHG Level Limit DO SIL 2/3 SIL 2 SIL 2 Level, 4-20mA Level 4-20mA Limit A DO Limit B DO Level, Temperature, Pressure Modbus V1 others Level Limit DO Level Limit DO IEC SIS loop Logic Solver PLC Tankvision Scanner API 2350 SIS Logic Limit HiHi DO Ethernet OPC OPC Other values required For Operator Ethernet OPC Level, Temperature, Volume, Pressure, Alarms, Ethernet TCP HMI Limit HiHi Display Limit Hi Display Fill Limit Display Operator Limit A Operator Limit n Overfill Prevention Tank Inventory Measurement Inventory System Slide 49

47 Products Solutions Services Reliable. Safe. Cost Effective. The Innovative Offering Electronic dp for Level Measurement - Deltabar FMD71/72 Slide 53

48 Level Measurement in Pressurized Tanks Deltabar electronic dp for impulse line and capillary-free level measurement in vacuum or pressurized tanks Right sensor technology for the application: Ceraphire ceramic cell Metal cell Start by click the animation Proven established technology utilized in a new innovative way: 2 sensors 1 transmitter 1 signal output to control system Slide 54

49 Eliminate Mechanical Issues of the Past Differential pressure (dp) most used level measurement technology Issues with traditional, mechanical dp measurement using impulse lines or capillaries can lead to: Less accuracy Less process safety Greater total cost of ownership Especially on tall tanks or vessels with varying ambient temperatures Slide 55

50 Eliminate measurement drift up to 95% Eliminate measurement drift due to ambient temperature changes up to 95% with Deltabar FMD72 electronic dp! Electronic dp Capillary system LP 2.9 psi/ 200mbar 2.9 psi/ 200mbar max. 160 F (70 C) 26ft (7.9m) FMD72 FMD78 HP 26ft (7.9m) min. +77 F (25 C) Total performance ± 0.23% ± 0.72in (18mm) No influence from varying ambient conditions!!! Performance (offset capillary) ±4.5% 8.58in (218mm) Slide 56

51 Response Time Electronic dp vs. Capillaries With capillaries process pressure is transmitted via oil filling to process membrane of the sensor. Response time with capillaries depends on: Capillary length Capillary diameter Viscosity of fill fluid Sensor URL Calculation with Applicator Sizing Diaphragm seal With electronic dp, the response time is the time needed to transmit the pressure within the oil filling of the senor Independent from mechanical influences No application dependent calculation needed Slide 57

52 Calculation of Total Performance for Capillary System Use Applicator Sizing Diaphragm Seal to get the capillary performance related to the process conditions of a capillary system (FMD78) Enter maximum sensor range, adjusted span & process connection Enter capillary length Enter ambient temperature of low pressure side of capillary (top side of the tank) Get the automatic calculated offset of the diaphragm Slide 58

53 Calculation of Total Performance for Electronic dp Use Applicator Sizing Electronic dp to get the total performance related to the process conditions of Deltabar FMD71/72 Enter maximum level & maximum head pressure Automatic calculated measuring performance Choose automatic sensor selection to get the process optimized sensor ranges Slide 59

54 Spare Concept of Deltabar FMD72 electronic dp Reduce out-of-service time and repair costs by more than 90% E.g. damaged capillary tube vs. damaged cable of Deltabar FMD71/72 max. Spare part needed: Spare part needed: min US$ 300 US$ Replacement of the whole capillary system necessary Time of replacement (in case the right system is on stock): 5 hours Replacement just of the cable Time of replacement: 30 min. Slide 60

55 Eliminate Plugging of Impulse Lines to Increase Safety Mechanical dp measurement using impulse lines p c Plugging due to crystallizing media nitrogen purging plugged lines Plugging by iced media heating of impulse lines High maintenance effort g p head T h h c Eliminate these issues with electronic dp: Maintenance-free impulse line h b Increase the safety with Deltabar FMD7x by reliable measurement as no plugging can occur. Save money at the same time as no maintenance/ heating/ purging is required. Slide 61

56 Multivariable Level Measurement Additional process control by additional information available via HART Level Differential pressure Head pressure Sensor temperature Control the head pressure for additional safety Improve process reliability and safety thanks to additional process variables used for advanced maintenance. At the same time, save money with multivariable device instead of single devices for level (dp), head pressure and sensor temperature. LP HP Slide 70

57 Suitable Housings for Each Application Ensured durability of materials reduces maintenance efforts and ensures a reliable and safe process Stainless steel and aluminum housings available Highest flexibility in material selection Depending on ambient conditions, material of sensor modules and transmitters could be varied Slide 72

58 Sensor Module Cables Durable But Still Flexible Cable material PE-X Cross-linked polyethylene Highest chemical resistance Improved low-temperature properties Optimized for outdoor applications C Halogen-free One cable side with M12 plug NEMA4x/6P (IP66/IP68) and open wires at the other side Allows highest flexibility thanks to freely adjustable length No water ingress into the sensor module electronic part caused by water column in conduit Flexible, durable and application-oriented cable concept results in a doubtless usage Slide 73

59 Continuous Health Indication for Doubtless Reliability FMD7x offers worthy information to save costs and lots of time in your plant maintenance Process diagnostics Variability index Statistical process monitoring Process performance index Pump diagnostics Oil Heater Q TC DT TT PT Boiler with waste solvent Distillation Column Loop diagnostics Level loop diagnostics Measurement loop diagnostics Cascade loop diagnostics Fieldbus communication diagnostics FMD7x a perfect basis for more sophisticated diagnostic coverage in your plant Device Diagnostics Electronic diagnostics Temperature values Pressure bumps Valid configuration diagnostics Slide 75

60 Increase Reliability Eliminate measurement drift due to ambient temperature changes up to 95% Multivariable level measurement: HART -based differential pressure, head pressure and sensor temperature from one system Continuous system health indication via HART -based diagnostics Faster response time than traditional capillary systems up to 10 times faster! Standard cabling connections provide flexibility Slide 76

61 Questions? Slide 77

62 More information on our web site Slide 78

63 Thank you for your attention Gerhard Jansson Slide 79