Rosemount 3051S Electronic Remote Sensors A Digital Upgrade to a Proven Technology.
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Transcript of Rosemount 3051S Electronic Remote Sensors A Digital Upgrade to a Proven Technology.
Rosemount 3051SElectronic Remote SensorsRosemount 3051SElectronic Remote SensorsA Digital Upgrade to a Proven Technology
[File Name or Event]Emerson Confidential27-Jun-01, Slide 2
Slide 2
DP Level is a Proven and Successful Technology DP Level is a Proven and Successful Technology
Straightforward measurement technique Easily verified and calibrated Flexibility enables use in variety of
applications (mass, density, interface)
Wet Leg Dry LegTuned-System Balanced System
DP 30%
Process Level Market by Technology*
Radar17%
Ultrasonic12%
Other26%
3051S ERS
NEW
GravitySpecific
PressureLevel
Switches15%
*VDC Global Process Level (2005), ARC Global Radar Study (2008), F&S Global Level Sensors (2005)
[File Name or Event]Emerson Confidential27-Jun-01, Slide 3
Slide 3
New 3051S Electronic Remote Sensors Enhance DP Level TechnologyNew 3051S Electronic Remote Sensors Enhance DP Level Technology
Wire
4-20 mA
DP = PHI – PLO
PHI
PLO DP Calculated Electronically• Two Pressure Sensors• Electronics Featureboard
Utilizes Proven 3051S Sensor Platform
Two-Wire 4-20 mA Output with HART
[File Name or Event]Emerson Confidential27-Jun-01, Slide 4
Slide 4
3051S ERS Provides Additional DP Level Capabilities3051S ERS Provides Additional DP Level Capabilities
Simplified Installations
Improved Performance
Simplified Maintenance & Spares Inventory
Access to New Information
Synchronized & Integrated Solution
Wire
4-20 mA
DP = PHI – PLO
PHI
PLO
[File Name or Event]Emerson Confidential27-Jun-01, Slide 5
Slide 5
3051S ERS Architecture Supports Flexible Installations
3051S ERS Simplifies Installation Practices3051S ERS Simplifies Installation Practices
3051SAL with Featureboard
3051SAL
Remote Display with Featureboard 3051SAM with
level flanges
1
1
2
3
3. Perform a system zero trim– Establishes true zero-based DP measurement– No zero elevation calculation required
2. Wire sensors together– Non-proprietary electrical wire– Easy to install around catwalks, on
distillation columns, etc.– Eliminate insulation and heat tracing
1. Independently install each sensor– Direct-mount without pipe stand, brackets,
and other hardware– Can be installed by a single instrument tech
3051SAM 3051SAM with Featureboard
[File Name or Event]Emerson Confidential27-Jun-01, Slide 6
Slide 6
3051S ERS Digital Architecture Delivers Improved Performance3051S ERS Digital Architecture Delivers Improved Performance
Direct Connection to Tank Reduces Time Response
Digital Architecture Eliminates Measurement Drift
Direct-Mounted ERS Transmitter
Transmitter with 10 ft (3 m) Capillary
0.5 sec.2.5 sec.
Evaporation
Wet Leg Dry Leg
Condensation
Fill Fluid Density & Volume Changes with
Temperature
Capillary 3051S ERS System
Electrical Wire
Digital architecture eliminates temperature
effects
[File Name or Event]Emerson Confidential27-Jun-01, Slide 7
Slide 7
3051S ERS Simplifies Maintenance and Spares Inventory3051S ERS Simplifies Maintenance and Spares Inventory
Simplify spares inventory & standardize on common ERS
components
Replace one transmitter vs. entire capillary assembly
• Corrosion• Process-coated diaphragm• Hydrogen permeation
[File Name or Event]Emerson Confidential27-Jun-01, Slide 8
Slide 8
System DP
20.23 psi
P-Hi Pressure
70.89 psi
50.66 psi
P-Lo Pressure Scaled Variable
0
100
200300
400
500
600
153.84 GALNS
P-Hi Module Temperature
P-Lo Module Temperature
-50 200
-8.33
33.33
75116.67
158.33
-50 200
-8.33
33.33
75116.67
158.33
105.5 deg.F
82.8 deg.F
3051S ERS Provides Greater Insight Into Your Process3051S ERS Provides Greater Insight Into Your Process
Automatic & synchronized DP calculation
Monitor PHI and PLO pressures in real-time
System DP
20.23 psi
P-Hi Pressure
70.89 psi
50.66 psi
P-Lo Pressure Scaled Variable
0
100
200300
400
500
600
153.84 GALNS
P-Hi Module Temperature
P-Lo Module Temperature
-50 200
-8.33
33.3375
116.67
158.33
-50 200
-8.33
33.3375
116.67
158.33
105.5 deg.F
82.8 deg.F
System DP
20.23 psi
P-Hi Pressure
70.89 psi
50.66 psi
P-Lo Pressure Scaled Variable
0
100
200300
400
500
600
153.84 GALNS
P-Hi Module Temperature
P-Lo Module Temperature
-50 200
-8.33
33.3375
116.67
158.33
-50 200
-8.33
33.3375
116.67
158.33
105.5 deg.F
82.8 deg.F
System DP
20.23 psi
P-Hi Pressure
70.89 psi
50.66 psi
P-Lo Pressure Scaled Variable
0
100
200300
400
500
600
153.84 GALNS
P-Hi Module Temperature
P-Lo Module Temperature
-50 200
-8.33
33.33
75116.67
158.33
-50 200
-8.33
33.33
75116.67
158.33
105.5 deg.F
82.8 deg.F
Scaled Variable converts DP into level & volume measurements
Process alerts enable proactive maintenance practices
[File Name or Event]Emerson Confidential27-Jun-01, Slide 9
Slide 9
20-Point Scaled Variable Simplifies Configuration & Commissioning20-Point Scaled Variable Simplifies Configuration & Commissioning
Automatically convert DP into level, volume, mass, or other variables
25 mbar = 17.9 LITER
3 Easy Configuration Options
1 Direct• Manually provide up to 20
“DP vs. Scaled” pairings
2 Tank Formulas• Scaled Variable using basic
tank dimensions
3 Strapping Table• Scaled Variable using tank
strapping table
[File Name or Event]Emerson Confidential27-Jun-01, Slide 10
Slide 10
• Not synchronized• 2x wiring costs• 2x required I/O• DCS programming• Difficult to “zero” DP
3051S ERS Provides an Easy, Integrated Solution3051S ERS Provides an Easy, Integrated Solution
P2
P1
P1
P2
DP
∆P
DP
∆P
PLO
PHI
Do-it-Yourself (Two Transmitters) 3051S ERS
• Synchronized measurements• Single 2-wire 4-20mA loop• No DCS programming• Easily zeroed & calibrated
No error from change in static pressure (∆P)
[File Name or Event]Emerson Confidential27-Jun-01, Slide 11
Slide 11
Chevron Phillips Chemical (Borger, TX) Achieved Success with 3051S ERS Chevron Phillips Chemical (Borger, TX) Achieved Success with 3051S ERS
CHALLENGE– Bridle with magnetic float and unreliable
heat tracing– False level measurement & unplanned
shutdowns
SOLUTION– 3051S ERS easily retrofitted entire bridle
assembly– Digital architecture eliminated need for heat
tracing
RESULTS– No unplanned shutdowns since installation
of 3051S ERS (3+ years)
Application• 30 ft (9 m) process
storage tank• Ambient Temp
0 to 100 F (-17 to 38 C)
“We have had no lost production and better on-stream operation since installing ERS”- Tim Anderson, I&E Reliability Team Leader, Chevron Phillips Chemical, Borger, TX
[File Name or Event]Emerson Confidential27-Jun-01, Slide 12
Slide 12
Oil Refinery Eliminates Unplanned Shutdowns on Reactor with 3051S ERSOil Refinery Eliminates Unplanned Shutdowns on Reactor with 3051S ERS
CHALLENGE– Frequent, unplanned plant shutdowns– Caused by plugged lines on pneumatic
transmitter with wet leg
SOLUTION– 3051S ERS assembly with FFW
flush flanged seals RESULTS
– 100% measurement reliability since installation (3+ years)
– No work orders or requests for troubleshooting
Application• Alkylation reactor• Level measurement
of effluent liquid
The 3051S ERS assembly with flanged seals was easily retrofitted on the Alkylation reactor and eliminated unplanned process shutdowns.
[File Name or Event]Emerson Confidential27-Jun-01, Slide 13
Slide 13
Austrian Pulp and Paper Mill Decreases Maintenance Costs with ERS TechnologyAustrian Pulp and Paper Mill Decreases Maintenance Costs with ERS Technology
CHALLENGE– Excessive maintenance costs on wet leg
installation• Plugged lines• Heat tracing• Vacuum spikes
– Suboptimal black liquor output
SOLUTION– 3051S ERS system
RESULTS– Elimination of heat tracing and water
purging– Increased reliability and repeatability of level
measurement
ApplicationLevel measurement on black liquor vessel
Zellstoff Pöls Austria was able to address reoccurring maintenance problems and improve their level measurement by upgrading to a 3051S ERS system.
[File Name or Event]Emerson Confidential27-Jun-01, Slide 14
Slide 14
Pulp and Paper Mill Reduces Downtime with Digital 3051S ERS ArchitecturePulp and Paper Mill Reduces Downtime with Digital 3051S ERS Architecture
CHALLENGE– Approx. one unplanned shutdown per month– Pump cavitations– Reoccurring problems with wet legs
• Plugged impulse lines• Maintaining level in wet leg
SOLUTION– 3051S ERS system
RESULTS– Elimination of wet leg– Only one shutdown over 2-year period– Process runs in automatic close to 100% of
time
ApplicationVacuum tank on lime mud filter
“The continued uptime with this instrument has built operations’ confidence in the measurement itself and has allowed the process to be run in automatic close to 100% of
the time”
[File Name or Event]Emerson Confidential27-Jun-01, Slide 15
Slide 15
Biotech Facility Increases Throughput on Fermentation Vessel with 3051S ERSBiotech Facility Increases Throughput on Fermentation Vessel with 3051S ERS
CHALLENGE– Inconsistent batches– 3-5% measurement error– Unable to calculate yield
SOLUTION– 3051S ERS system with hygienic Tank-
Spud seals
RESULTS– Measurement error improved to less than <
0.5%– Drastic time response improvement– Achieved consistent, high-quality batches
ApplicationLevel measurement on enzyme fermentation vessel
“This application used to be our biggest headache, but now the fermentor is used as our first choice depending on the quality of product needed.”
[File Name or Event]Emerson Confidential27-Jun-01, Slide 16
Slide 16
Solvay Decreases Operations & Maintenance Costs with 3051S ERSSolvay Decreases Operations & Maintenance Costs with 3051S ERS
CHALLENGE– Costs and challenges associated with DP
transmitter and wet leg installation• Salt crystals would plug impulse lines• Required complicated water injection system• Evaporator had to be taken off line frequently
SOLUTION– 3051S ERS with EFW extended diaphragm
seal
RESULTS– Extended seal used at bottom of tank
eliminated plugging– Digital architecture enabled optimized
control
Application• Brine level
measurement• 33 ft (10 m)
evaporator“The ERS system has been installed for months, much to our total satisfaction” - Jean-Marc Deconto, Solvay engineer
[File Name or Event]Emerson Confidential27-Jun-01, Slide 17
Slide 17
Chemical Company Eliminates Excessive Maintenance Costs with 3051S ERSChemical Company Eliminates Excessive Maintenance Costs with 3051S ERS
CHALLENGE– Excessive maintenance costs:
• Troubleshooting dry leg installation• Daily field visits to check distillation packing
– Measurement drift from temperature variations
SOLUTION– 3051S ERS system
RESULTS– No unplanned shutdowns for over one year– Able to accurately monitor health of packing
in tower without manual trips to field– Eliminated costs associated with
troubleshooting installation
Application20 ft (8.3 m) Glycerin refining tower
“Since installing ERS, we never hear any complaints from our maintenance or operations group. As far as I am concerned, no news is good news.” - Project engineer
[File Name or Event]Emerson Confidential27-Jun-01, Slide 18
Slide 18
Silicon Manufacturer Reduces Inventory Costs with 3051S ERSSilicon Manufacturer Reduces Inventory Costs with 3051S ERS
CHALLENGE– Excessive capillary caused measurement
error > 5%– Inconsistent batches
• Material shortages• High scrap rates
SOLUTION– 3051S ERS system
RESULTS– Accurate level measurement– Achieved consistent batches– No unplanned shutdowns
ApplicationLevel control in silicon holding tank
The long lengths of capillary with the previous installation were completely eliminated with the digital architecture of the 3051S ERS system.
[File Name or Event]Emerson Confidential27-Jun-01, Slide 19
Slide 19
3051S ERS
System
Proven ERS Applications1. Distillation Tower2. Chemical Holding Tank3. Enzyme Fermentation4. Batch Tank5. Vacuum Tank6. Chemical Reactor7. Black Liquor Level8. Beer Storage9. Glycerin Refining10. Starch Level
ERS Applications Characteristics• Tall Spans• Temperature Variation• Heat Tracing• Plugged Impulse Lines• Low Static Pressure• Excessive Impulse
Piping / Capillary• Measurement Drift
New 3051S Electronic Remote Sensors Have Proven SuccessesNew 3051S Electronic Remote Sensors Have Proven Successes
[File Name or Event]Emerson Confidential27-Jun-01, Slide 20
Slide 20
3051S ERS Compliments Traditional DP Level Technology3051S ERS Compliments Traditional DP Level Technology
100 in.H20
100 psi
Tuned-System™ Assembly
• Sensor sized on DP column only • DP Sensor Span = 100 in.H20
Electronic Remote Sensors
• Sensors sized on amount of static pressure + DP column
• GP Sensor Span = 103.6 psi (2868 in.H20)
100 PSI
100 in.H20
High Pressure Application Example
ERS
Tuned-System±2.8 in.H20
±1.4 in.H20
25 F Ambient Temperature Change
VS
[File Name or Event]Emerson Confidential27-Jun-01, Slide 21
Slide 21
Traditional DP Level Technologies Still Have Key Applications and BenefitsTraditional DP Level Technologies Still Have Key Applications and Benefits
Tuned-System
Assembly
Application Characteristics• Short Spans• High Pressures• Indoor Vessels• Stable Temperatures• Simple Installations• Wireless
Traditional DP Level Technologies• Tuned-System
Assembly• Balanced Capillary
System• DP transmitter with wet
leg• DP transmitter with dry
leg
[File Name or Event]Emerson Confidential27-Jun-01, Slide 22
Slide 22
Achieve Success with Rosemount DP Level in More Places than Ever BeforeAchieve Success with Rosemount DP Level in More Places than Ever Before
Wet Leg Dry LegTuned-SystemBalanced System3051S ERS
Measurements• Pressure• Level• Volume• Interface• Density• Mass• Flow
Applications• Hot & cold temperatures• Corrosive & viscous processes• Vacuums• Foam, agitation, & other tank
disturbances• Vessels & towers
Industries• Refining• Pulp and paper• Oil & gas• Chemical• Food and beverage• Biotechnology