DigiTrace NGC-family

DigiTrace NGC-family The world beyond the MoniTrace 200N Robert Kuipers Electronics Marketing Manager Ken Wilson Industrial Sales Manager Peter Sirs UK/Nordics Regional Sales Manager Bruno Guinand Business Development Manager ( (Kashagan Project) DigiTrace NGC-20

Tyco Thermal Controls.. 2

Major Global Service Centres, Local Response Edmonton,C A Chicago,USA Amstelveen, NL Washington, UK Mudersbach, DE Houston,USA Philadelphia, USA Shanghai CN Tyco Thermal Controls 2000 Employees Worldwide 50 Locations 6 Manufacturing Facilities 9 Major Service Centers Mumbai IN 3

Trends in control and monitoring systems for industrial heat-tracing applications Increased importance of control and monitoring Safety requirements Less plant personnel Narrower temperature range for increased production quality and yields Lower operating and maintenance cost leading to enhanced requirements for Centralized access to critical information on heat-tracing system status Functionality specific to requirements of heat-tracing installations Data for analysis of trends and simplified fault finding 4

Why Do We Need Control Constant Wattage 30 25 Constant Wattage heating cable Max. Heat loss (min ambient) Watts/M 20 15 Min. Heat loss (max ambient) 10 5 0 10 20 30 40 50 60 70 80 Pipe temperature, C 5

Why Do We Need Control Constant Wattage 30 25 Constant Wattage heating cable Max. Heat loss (min ambient) Watts/M 20 15 Min. Heat loss (max ambient) Line ID 10 Pipe Insulation diameter Thickness 5 Heater Catalog No Maintain Temp. Min. Ambient Temp. Min. Controlled Temperature Max. Ambient Temp. Max. Controlled Temperature in mm C C C C C H2O line 5 C 2 30 20FHT2-CT 5-40 18 40 92 0 H2O line 70 C 2 50 30FHT2-CT 70 10 20 30 40 50-40 60 70 72 80 40 139 Pipe temperature, C Steam line 120 C 2 50 30FHT2-CT 120-40 153 40 210 6

Why Do We Need Control Self Regulating 30 25 20 Power output Self- Regulating heating cable Max. Heat loss (min ambient) Watts/M 15 10 Min. Heat loss (max ambient) 5 0 10 20 30 40 50 60 70 80 Pipe temperature, C 7

Why Do We Need Control Self Regulating 30 25 20 Power output Self- Regulating heating cable Max. Heat loss (min ambient) Line ID Watts/M 15 Pipe temperature, C Min. Heat loss (max ambient) Pipe Insulation Min. Min. Max. Max. 10 Nominal Thickness Heater Maintain Ambient Controlled Ambient Controlled Dia (Inner) Catalog No Temp. Temp. Temperature Temp. Temperature 5 in mm C C C C C H2O line 5 C 2 30 5BTV2-CT 5-40 9 40 49 H2O line 70 C 0 2 50 20QTVR2-CT 70-40 70 40 94 10 20 30 40 50 60 70 80 Steam line 120 C 2 50 15KTV2-CT 120-40 121 40 148 8

Self Regulating with Thermostatic Temperature Control 30 25 Self- Regulating heating cable SET-POINT Watts/M 20 15 10 Heat loss (min ambient) Heat loss (max ambient) 5 0 10 20 30 40 50 60 70 80 Pipe temperature, C 9

Introduction to PASC control (Proportional Ambient Sensing Control) Heat Loss = k A T insulation pipe size fluid temp ambient temperature We only need to sense the ambient temperature to know how to control the pipe temperature 10

Proportional Ambient Sensing Control: PASC Thermostat Set point (Pipe temp) OFF ON OFF 100% Time Duty Cycle (ON /OFF ratio) 0 T minimum T ambient T maintain Ambient Temperature 11

Practical example: Ambient Control Freeze protection system controlled by an ambient sensing thermostat. 100 % 10W/m Power provided Power usage 0-30 C Ambient Temperature Tset (5 C) 12

Practical example: PASC Control Freeze protection system controlled using PASC 100 % 10W/m Power provided Power usage 0-30 C Ambient Temperature Tset (5 C) 13

Savings on a yearly basis per 100 meter heat-tracing cable Line ID Insulation Thickness Maintain Temp. Heater Min. Ambient Temp. Min. Controlled Temperature Max. Ambient Temp. Max. Controlled Temperature Pipe Heat Loss Heater Output Control method mm C C C C C W/m W/m 3" H2O line 70 C SR 50 70 20XTV2-CT -40 85 40 129 38,2 48,8 Uncontrolled 3" H2O line 70 C SR 50 70 20XTV2-CT -40 70 40 96 38,2 48,8 PASC 3" H2O line 70 C SR 50 70 20XTV2-CT -40 70 40 70 38,2 48,8 Line Sensing Assumption: Average Temperature 10 C Heat Loss At 10 C Power Output cable at 70 C Perfect energy balance 46% 22,6 W/m 48,8 W/m Watt kwhr per year Price kwhr Energy cost / year Savings Uncontrolled -> Cable activated 100% for 100m cable: 4880 42749 0,10 4.275 0 PASC -> Cable activated about 55% for 100m cable: 2684 23512 0,10 2.351 1.924 Line sensing for 100m cable: 2259 19793 0,10 1.979 2.296 * The smaller the overshoot at min. Ambient, the more savings PASC will bring

The Next Generation in Heat-Tracing Control Tyco Thermal Controls has made significant investments to further enhance its offering of control and monitoring solutions Today, we present the DigiTrace NGC family of enhanced control and monitoring for industrial heat-tracing systems 15

DigiTrace NGC A complete product family DigiTrace NGC-30: Central Monitoring and Central Control Multi-circuit control, monitoring and power distribution system Positioned for lowest total installed and operating cost DigiTrace NGC-20: Local Control and Central Monitoring Single circuit control, monitoring system with central monitoring Positioned for highest reliability and lowest total installed and Operating cost DigiTrace NGC-UIT: User Interface Terminal DigiTrace NGC-40: Enhanced multi-circuit control, monitoring and power distribution system Positioned for highest reliability and offering most features 16

DigiTrace NGC-30 Central Control Central Monitoring Enhanced control and monitoring for industrial heat-tracing systems

DigiTrace NGC-30 The advanced multi-circuit control, monitoring and power distribution system for heat-tracing applications Control and monitoring of up to 260* loops Capability to monitor temperature, groundfault currents, operating currents and voltages User interface terminal with touch screen technology Data logging for trending, fault finding and other analysis with DigiTrace supervisor *: System configuration dependent 23

DigiTrace NGC-30: Central Control Central Monitoring Distribution Panel: RCDs + Control 1 power cable per circuit 1 pair of wire for temperature sensor per circuit 24

DigiTrace NGC-30 system overview High level communication User interface DigiTrace NGC-components 25

DigiTrace NGC-30: User Interface Controllers Temperature measurement Configuration & monitoring Control Output Measure CRM & CRMS CTM PT100 panel or remotely panel field 26

Card rack modules exist in 2 types: Type 1: CRM for driving contactors Type 2: CRMS for driving solid state relays (SSR) 5 control loops on one board CRM Mechanical relay control On / Off, and PASC control CRMS Solid state relays for hazardous locations Additional features: Proportional Power-limiting Soft start / staggered start Alarm conditions Low / high temperature RTD failure Communications failure Ground-fault Low / high current Set independently for each loop 27

Ground fault and current measurement Via a current transformer the following parameters are measured: Net current loss in EHT system Ground Fault Total current to field Up to 60 A calibrated (100 A measured) 28

Ground fault measurement / current measurement setup Ground fault and current measurement setup screens on user interface terminal 29

Automatic self-test function Features Configurable self-test function Benefit: The heat-tracing system integrity is continuously monitored Malfunctions are reported to user via clear messages No surprises when you don t need them 30

DigiTrace NGC-30 network architecture Connection to DCS Ethernet RS-485 RS-232 Protocol ModBus 31

DigiTrace NGC-30 panels supplied as complete systems from small to large Last year more than 70 systems in Europe with more than 5000 EHT circuits 32

DigiTrace NGC-30 Central control of heat-tracing systems DigiTrace NGC-30 - a central overview of the heat-tracing system integrity Ease of use by colour touch screen technology DigiTrace Supervisory software Access to all information simplifies maintenance Data logging, trending, reports, drawings All heat-tracing control systems in one application Almost unlimited number of circuits... from any location in the world Enhanced control and monitoring for heat-tracing Monitoring of ground fault current helps to identify and locate water ingress or mechanical damage Automatic heat-trace system integrity checks Distributed architecture reduces total installed cost and many more features 33

DigiTrace NGC-20 Local Control Central Monitoring Enhanced Control and Monitoring system for Industrial Heat-Tracing applications DigiTrace NGC-20

DigiTrace NGC-20 System overview Local control Central Monitoring High level communication User interface DigiTrace NGC-20 controllers Smart Thermostat in the field 35

DigiTrace NGC-20: Local Control Central Monitoring Reduction of cabling and simplifies panel design Simplified Panel design Power cabling reduction No RTD wiring 36

Display on DigiTrace NGC-20 for direct indication Feature: Local display Benefit: Direct indication of temperature and alarms 37

Control and Monitoring Assistant for full accessibility in field Feature: User interface through portable handheld programming device Benefit: Hand held device offering a means of monitoring the electrical heat-tracing system in the field without opening the control unit 38

Control and Monitoring Assistant for full accessibility in field DigiTrace NGC-20 fully configurable via handheld device All parameters available via easy-to-use displays Full monitoring and alarm capability 39

User interface terminal (UIT) The UIT Is a central element in the DigiTrace-NGC family Is used for monitoring and configuration purposes Is a panel mounted device Has colour display with touch screen functionality The UIT is used for: Configuration Monitoring Alarming of various DigiTrace products like the DigiTrace NGC-20! 40

DigiTrace NGC-20 : available with integrated Intelligent Safety Temperature Limiter DigiTrace NGC-20 controller available in 2 versions ATEX IEC Ex For worldwide coverage 1. DigiTrace NGC-20-C-E (Control unit): Hazardous area approved controller (zone 1, 2, 21 and 22) 2. DigiTrace NGC-20-CL-E (Control and Limiter Unit): Hazardous area approved controller (zone 1, 2, 21 and 22) including Intelligent Safety Temperature Limiter certified as SIL 2 device Separate temperature sensor input 42

When do we need a Intelligent Safety Temperature Limiter? A Safety Temperature Limiter is required when the heating application: Is installed in Zone 1 / Zone 21 With control limited design Prevents temperature of heating cable go above T-class when controller fails Nuisance tripping due to high process temperature conditions requires manual reset in the field DigiTrace NGC-20 limiter is intelligent : Will only trip when heat-tracing is energised Prevents unnecessary intervention for maintenance personnel 43

Load shedding / Start-up reduces high peak load demands heat tracing can show high inrush currents. To reduce these high current peaks, the start-up of connected units the can be shifted in time in 16 different groups of DigiTrace NGC-20 Load shedding during emergency operation Group 1 Group 2 Group 3 Group 16 Group.. Group 4 Flexible grouping 44

Hybrid switch Continues monitoring of controller switching Feature: Dedicated control electronics per heating circuit and high current capacity of 25 A with hybrid switch Switching of the contactor is continuously monitored Alarms will be raised when the contactor is not switching as requested Benefit: Highest reliability and long lifetime, even at elevated circuit loads by dedicated electronics and hybrid switch Maintenance continues informed about the reliability of the controller 45

Junction boxes reduction Feature: Locally installed (on pipe) Heating cable directly connected Benefit: Direct heater connections reduce the number of field junction boxes, lowering power cable costs and maintenance cost 46

Circuit integrity monitoring of Electrical Heat- Tracing via DigiTrace NGC-20 Feature: Monitoring of status information: 1. temperatures, 2. supply voltage, 3. Earth leakage and 4. operating current; with fully configurable alarms Benefit: 1. Permanent supervision of the integrity of the heat-tracing circuit. 2. Detailed problem reporting simplifies maintenance and increase personnel safety and now in more detail 47

DigiTrace NGC-20: continues monitoring ground fault / earth leakage current DigiTrace NGC-20 system monitors earth leakage current at ma level Information The controller provides alarm and trip settings for earth leakage The alarm set point is configurable. Range is between 10 ma and 200 ma Corrective action The controller provides earth leakage trip settings Range between 10 ma and 200 ma Alarm trip point < Trip set point < Breaker trip point Earth leakage warning can be enabled / disabled Earth leakage trip can be enabled / disabled 48

Setup Earth leakage Measurement with 1. Hand held 2. User Interface Terminal 3. DigiTrace Supervisor 49

Current measurement Voltage measurement for EHT diagnostics The Current Transformer inside the DigiTrace NGC-20 measures the total Current to the heat-tracing cable. Voltage is measured alarms raised when voltage swings occur Energy consumption (KWh) circuit integrity 50

Automatic self-test function Feature: Configurable self-test function Benefit: The heat-tracing system integrity is continuously monitored Malfunctions are reported to user via clear messages No surprises when you don t need them 51

DigiTrace NGC-20 brings benefits of Local Thermostat & Central Monitoring together 52

DigiTrace NGC-20 Local Control Central Monitoring TTC World November 2009 53

DigiTrace NGC-20 Summary Local Control Central Monitoring leads to considerable cost saving 1. Reduction of Total Installation Cost (TIC) Via reduction of cabling and simplified panel design 2. Reduction of Total Operation Cost (TOC) By informing Maintenance personnel of Heat-Tracing specific information like Earth Leakage currents, Load Current, Voltage and Power usage and system integrity check results Via Local display, Hand held device, User Interface Terminal and DigiTrace Supervisor ATEX approved SIL 2 device 54

DigiTrace NGC-40 Product Overview

DigiTrace NGC-40: Central control with central monitoring with full flexibility DigiTrace NGC-40 inherits strong features and benefits from DigiTrace NGC-20 and DigiTrace NGC-30 + = Designed for highest reliability and customer requirements 56

DigiTrace NGC-40: Completing the story DigiTrace NGC-40: full flexibility complementing your requirements Single CPU per circuit offering highest reliability and flexibility Modules plug and play DIN rail mountable for flexible and optimized panel design Wiring is minimized by using CAN-based network 57

DigiTrace NGC-40 controller building blocks The DigiTrace NGC-40 system contains 5 different control components 1. Communications Bridge Module DigiTrace NGC-40-BRIDGE 2. Control Module DigiTrace NGC-40-HTC (single phase) DigiTrace NGC-40-HTC3 (3-phase) 3. I/O Module DigiTrace NGC-40-IO 4. Safety Temperature Limiter Module DigiTrace NGC-40-SLIM 5. Power Transfer Module DigiTrace NGC-40-PTM 58

DigiTrace NGC-40: Central Control & Monitoring with single CPU per circuit Advanced panel mounted multi-circuit control, monitoring and power distribution system for heat-tracing applications Each circuits is controlled by individual independent controller Capability to monitor temperature, groundfault currents, operating currents and voltages Digital input to override heat-tracing control output Power and current clamping to reduce inrush currents 1 phase and 3 phase controllers SIL 2 Safety Temperature limiter 15 User interface terminal with touch screen technology Data logging for trending, fault finding and other analysis with DigiTrace supervisor 59

DigiTrace NGC-40 Control Modules Covering single phase and three phase systems NGC-40-HTC Single phase controller Monitors GF and load current NGC-40-HTC3 Three phase controller Monitors current of each phase Monitors GF Loads up to 60A Current and Ground Fault measurement inside module 60

DigiTrace NGC-40 Control Module Temperature and Logic input driven Direct PT100 RTD Temperature input to the Control Module Digital input allowing remote alarm and heat-tracing Force-ON and Force-OFF functions 61

Control Module and Solid State Relays bringing Enhanced features & benefits for your heat-tracing Feature: Benefit: High switching capability For accurate temperature control Feature: Benefit: Current and Power limitation Prevent high inrush currents and control heat-tracing power output 62

Load shedding reduces high peak load demands Group 1 Group 2 Group 3 Group 4 Group 6 Group 5 Group 8 Group 5 Group 7 Group 5 Group 6 63

Automatic self-test function Feature: Configurable self-test function Benefit: The heat-tracing system integrity is continuously monitored Malfunctions are reported to user via clear messages No surprises when you don t need them 64

DigiTrace NGC-40-IO Module Providing flexible configuration possibilities Module offers: Four temperature sensor inputs One multi-purpose dry-contact input One Form-C output relay 65

DigiTrace NGC-40-SLIM Safety Temperature Limiter Module Independent device applications requiring high temperature safety lockout Up to 3 sensors for 3 phase systems! Output controls an independent contactor Intelligent limiter SIL2 certified: Functional safety as per IEC 61508 66

DigiTrace NGC-40 Bridge Connecting control to the User Interface Connecting the DigiTrace NGC-40 control to User Interface Terminal (UIT) DigiTrace Supervisor Software (DTS) DCS system (2011) Communication via: LAN RS-232 RS-485 67

Fully Compatible NGC Control System 68

DigiTrace Supervisor Bringing your heat-tracing information at the right spot at the right time

DigiTrace Supervisor The DigiTrace Supervisor (DTS) is a heat-tracing controller configuration and monitoring software package. It brings the heat-tracing control and monitoring facilities into the control room at the desk of the maintenance engineer or wherever wanted on the world 70

All comes together in the DigiTrace Supervisory Software Central access via software DigiTrace Supervisor Configuration and monitoring of all parameters of the entire installation (temperatures, alarms etc.) Client-server architecture Multi-access from locations wherever desired MS SQL server, enterprise class system Data logging for trending, fault finding and other analysis leading into predictive maintenance Less paper by integrating documentation and drawings into Supervisory Software 71

DigiTrace Supervisor is based on a client-server architecture SLAVE SERVER #1 NGC-20 NGC-20 Local engineer SLAVE SERVER #2 NGC-30 NGC-20 NGC-30 Porvoo Master Server NGC-30 SLAVE SERVER #3 NGC-40 Tyco Thermal Controls Service Team LAN/WAN NGC-40 NGC-40 72

DigiTrace Supervisor Configuration and monitoring DigiTrace Supervisor offers the following features: A graphical user interface for DigiTrace communication and controller products. A fully integrated alarm & event monitoring system with the ability to acknowledge and clear alarms as required. 73

DigiTrace Supervisor Configuration and monitoring DigiTrace Supervisor includes the following features (continued): Group displays for monitoring multiple controllers at the same time General and personal display settings possible 74

DigiTrace Supervisor Trending DigiTrace Supervisor includes the following features (continued): Logging & trending 75

DigiTrace Supervisor Batch, Recipe DigiTrace Supervisor includes the following features (continued): Batch & recipe processing, Scheduled events, Plant reference model for structuring controller on a logical way 76

DigiTrace Supervisor Reporting Reporting Alarms Configuration Users Location Communication Documentation link to device configuration and monitoring utilities 77

Scaleable architecture Three system sizes: 1. Single user/server PC (small systems) 2. Single server, multiple users (medium sized systems) 3. Multiple servers, multiple users (large systems - Enterprise) 78

DigiTrace Supervisor architecture Single server / up to 4 users (medium sized systems) Network Maintenance Engineer Operations Master Server NGC NGC NGC Remote Support Internet via VPN 79

Project Example Support at 2000 km distance System in South of Spain Local access via User Interface Terminal Engineer 500 km away in Madrid Tyco support from Belgium 80

In Summary

We raise the maintenance level to a more required level with the DigiTrace NGC-family Maintenance is classified in four categories: 1. Feedback Monitor its condition and replace it just before it fails. 2. Predictive Replace it one standard deviation before it statistically fails. 3. Preventive Oil it, and it will last longer. 4. Reactive If it breaks, fix it. With optimized DigiTrace NGC-20, DigiTrace NGC-30 & DigiTrace NGC-40 mix to minimize Total Installation Cost (TIC) Total Operation Cost (TOC) 82

DigiTrace NGC A complete product family DigiTrace NGC-30: Multi-circuit control, monitoring and power distribution system Offers lowest total installed cost DigiTrace NGC-20: Single circuit control, monitoring system with central monitoring Offers highest reliability and lowest total installed cost User Interface Terminal DigiTrace NGC-40: Enhanced multi-circuit control, monitoring and power distribution system Offers highest reliability and offering most features 83

Q & A - Additional general trace heating discussions Vendor recommendations on temperature control on frost lines in cold ambient temperature designs Vendor recommendation on start-up temperature for circuits Vendor experience of designing against hydrate formation Ability of water lines down to ½ to withstand 1 hour power outage without ice formation Vendor suggestions for early estimate of FFD trace heating load based on P&IDs and plot plans Reference list and/or brief summary of projects of similar scope and in similar environmental conditions Summary of experience in Kazakhstan with mention of lessons learnt on compliance with local regulations, logistics, installation etc 84

THANK YOU FOR YOUR ATTENTION ANY QUESTIONS???