Post on 01-May-2018
02/20/2015
Products Solutions Services
Tech days Edmonton
Next Level InstrumentationBy Ing. Rob Vermeulen, Bec
By Gerhard Jansson, Application Support Level + Pressure at SC-CA
Slide 1 RV / GJ
02/20/2015
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 RV / GJ
02/20/2015
Heartbeat Technology™ - elements
Heartbeat Verification
Heartbeat Diagnostics
Heartbeat Monitoring• ------------------• ------------------• ------------------• ------------------• ------------------
Pass / Fail
Heartbeat Technology™
Slide 3 RV / GJ
02/20/2015
Continuous output of data influenced by process
Continuous self-diagnostic of Level, Flow and Pressure instruments
On demand confirmationof instrument functionality
Heartbeat Technology™ - in operation
Heartbeat Verification
Heartbeat Diagnostics
Heartbeat Monitoring• ------------------• ------------------• ------------------• ------------------• ------------------
Pass / Fail
Slide 4 RV / GJ
02/20/2015
Onboard diagnostics – running in the background
Continuous automatic internal check in the device
• Logic program run control
• Reference pulse HF
• Quartz synchronization
• Measuring cycle time
• Supply voltage
• Temperature
• Check sum RAM
• Cable breakage
Check
• 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 RV / GJ
02/20/2015
Measurement signal Verification – Multi Echo Tracking
Animation to describe the Multi-Echo Tracking(explained on a Micropilot)
Start by click the animation
Slide 6 RV / GJ
02/20/2015
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 RV / GJ
02/20/2015
Process monitoring – the “Heart beat” of your process
Animation of foam measurement(explained on a Micropilot)
Start by click the animation
Slide 8 RV / GJ
02/20/2015
Do I need “software” to monitor Heart beat?
Plastic Alu 316L
4-20mA 4-20mA
Housing
4-20mAPFS
4-20mADC
4-20mAAC
Approval
Electronics
ATEX
2-wire 4-wire
HistoROM+
mechanical buttons oroptical buttons for operation
from outside
Display
Remote DisplayFHX50
4-20mA –
FMR50 FMR51 FMR56 FMR57FMR54FMR52 FMR53+ 100mm horn
up to 250°Cor 450°C up to 400°C
basic solid solidbasic liquid liquid hygienic/corrosion resistant
insulated HT/HP
+ 100mm horn+ planar
316Lplastic
Slide 9 RV / GJ
02/20/2015
….. But you can. DTM start page with clear instrument health status
Example for Micropilot
Health status
Health status
F/C/S/MClear diagnostic message +
Remedy information
Slide 10 RV / GJ
02/20/2015
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 RV / GJ
02/20/2015
HistoROM
The HistoROM isfixed in the housing(can not be lost or“forgotten”)
• 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)
• 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 RV / GJ
02/20/2015
Animation HistoROM
Start by click the animation
Slide 13 RV / GJ
02/20/2015
HistoROM
Electronic change during night shift
The HistoROM isfixed in the housing(can not be lost or“forgotten”)
Example HistoROM functionality
Slide 14 RV / GJ
02/20/2015
Extended HistoROM
• Coming free of charge with• Levelflex, Micropilot (HART SW 1.02.00)
• Storage of• Event recorder according to Endress+Hauser standard
• 100 events• 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
The HistoROM isfixed in the housing(can not be lost or“forgotten”)
Micropilot FMR5x – Next Level Instrumentation
Slide 15 RV / GJ
02/20/2015
Extended HistoROM – Event List – up 100 events
Micropilot FMR5x – Next Level Instrumentation
Slide 16 RV / GJ
02/20/2015
Extended HistoROM - Trend
• Visualization of up to 4 trend values• Visualization of events in correlation with trend values
Micropilot FMR5x – Next Level Instrumentation
Slide 17 RV / GJ
02/20/2015
Extended HistoROM - Statistics
• Statistical information about recorded values
Micropilot FMR5x – Next Level Instrumentation
Slide 18 RV / GJ
02/20/2015
Diagnosis: 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:
Button to read reference curve
Micropilot FMR5x – Next Level Instrumentation
Slide 19 RV / GJ
02/20/2015
Process monitoring – the “Heart beat” of your process
Build up on an antenna(explained on a Micropilot)
Start by click the animation
Slide 20 RV / GJ
02/20/2015
Products Solutions Services
Proof testing…. Necessary, Safe and Practical.
Next Level Instrumentation
Slide 24 RV / GJ
02/20/2015
Incidents Preceding Improved Safety Standards
Pernis Oil Refinery, HollandJan 20, 1968 (2 dead, 85 injured)
Flixborough, UKJun 1, 1974 (28 dead, hundreds injured)
Seveso, ItalyJul 10, 1976 (700 injured)
Bhopal, IndiaDec 2, 1984 (2,500 dead, 100,000 injured)
Piper Alpha, UK (North Sea)Jul 6, 1988 (165 dead, 61 injured)
Still happening…….
Slide 25 RV / GJ
02/20/2015
Still happening…….
Firefighters fight flames at the BP plant in Texas City after the July 28, 2005 explosion. (15 dead & 170 injured)
Still happening…….
Slide 26 RV / GJ
02/20/2015
The Buncefield fire - Sunday 11 December 2005Investigation 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 05.20 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 RV / GJ
02/20/2015
The Buncefield fire - Sunday 11 December 2005Investigation 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 RV / GJ
02/20/2015
So what can help prevent this in future?
Clear Application Reliable Measuring Principle
Correct Installation & Start-up
Regular Functional
Test
Safe Instrumented Solutions - Good Engineering is Crucial
Smart Proof
TestingSlide 29 RV / GJ
02/20/2015
Fixed Roof – SAFE LAHH Solutions
Levelflex – Guided Wave Radar, Time Domain ReflectometryMeasurement 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 RV / GJ
02/20/2015
Proof testing
• By expert inspection
• Proof test coverage depends on
inspection depth
MountingFunctional Safety
• 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
Fixed roof solutions
Guided Wave Radar (TDR)
Top
Liquiphant Side Top
Top adjustable
•IEC 61508 design•Proven in use•Suitable for SIL 2 / 3 (3 when used in omogeneousredundancy)•Switching in remote switch unit•Discrete output (relays)
•By expert inspection•Proof test coverage depends on inspection depth
Slide 31 RV / GJ
02/20/2015
Guided radar as over spill protectionLevelflex as SIL 2 overspill protection on Fixed roof tanks and LPG bullets
Slide 32 RV / GJ
02/20/2015
Products Solutions Services
Example – Level Continuous
Guided Wave Radar Levelflex FMP 5x
Start by click the animation
Slide 33 RV / GJ
02/20/2015
Smart Proof Testing without removal
MAX
MIN
Slide 34
3 step-by-step proof test procedures are available
Slide 34 RV / GJ
02/20/2015
SMART PROOF-Test Sequence “C”
Step 1 Deactivate SIL mode.
Step 2
Connect suitable measuring device
to the current output (recommended
accuracy better than ±0.1 mA)
Step 3Determine the safety setting: “level limit” or “level range”
MAX
MIN
Preparation and Tools
Slide 35 RV / GJ
02/20/2015
SMART PROOF-Test Sequence “C”
Step 4Start built-in
„SELFCHECK-Routine
Step 5
1. Electronic simulation of level
[79% just below MAX] 2. Verification of output
current [0-100% = 4-20mA]
Step 6
1. Electronic simulation of level
[81% just above MAX] 2. Verification of output
current [0-100% = 4-20mA] “16,96mA”
“16,64mA”“79%”
“81%”
Example HH e.g. at “80%”
Slide 36 RV / GJ
Proof test coverage, PTC = 0.93
02/20/2015
Floating Roof TanksIndependent High Level Alarms / Radar – Proof Testing external
External Swivel plate for functional
proof testing
Combined Swivel plate for functional
proof testing
Slide 37 RV / GJ
02/20/2015
Secure Switch Settings using Contact Plate
Slide 38 RV / GJ
02/20/2015
So what can help prevent this in future? Overfill Prevention Cabinets according to API 2350
Slide 39 RV / GJ
02/20/2015
Reports and recommendations
Slide 40
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 RV / GJ
02/20/2015
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 61511
• Tanks in fully automated operation…shall be equipped with an independent LAHH (Level Alarm High High) sensor (API2350 4.4.5.4.4)
• 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 (API2350 4.5.5.4)
• 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 (API2350 5.4)
Slide 41 RV / GJ
02/20/2015
Buncefield Report
Slide 42 RV / GJ
02/20/2015
Products Solutions Services
Example - Level switch
Tuning fork switch Liquiphant FTL5x, FTL7x Liquiphant Failsafe
Start by click the animation
Slide 43 RV / GJ
02/20/2015
Self Diagnostics Liquiphant M/S (FEL 51… 57)
Slide 44 RV / GJ
sensor
alarm0,4 s delayed
400fa-15%
fafa+ 6,5%
1500 f [Hz]
25 mm
1 inch
0
0
Immersion depth
corrosion
alarm60 s delayed
sensor
Alarm0,4 s delayed
normal operation
fa-15% switch point approx. 850 Hz
A
L
A
R
M
A
L
A
R
M
fa oscillation frequency in air
approx. 1 kHz
• Continuous monitoring of vibration frequency• Reliable alarm function with each electronic insert!
02/20/2015
Liquiphant SIL Product Portfolio today
Liquiphant M FTL50/51/51CLiquiphant S FTL70/71Nivotester FTL3x5 P
SIL2 MIN/MAX
PFM
Liquiphant M FTL50/51/51CLiquiphant S FTL70/71Nivotester FTL325N
NAMUR
Liquiphant S Failsafe FTL80/81/85Nivotester FTL825
PFM
SIL3 MAX
Liquiphant M FTL50/51/51CLiquiphant S FTL70/71Nivotester FTL3x5 P
(with Redundant installation)
PFM
FEL51, 2-wire ACFEL52, 3-wire DC-PNPFEL54, AC/DC DPDTFEL55, 8/16 mA
Liquiphant M FTL50/51/51CLiquiphant S FTL70/71
Slide 45 RV / GJ
02/20/2015
Proof-testing Electronic FEL 51/52/54/55
Liquiphant FTL 50/51/70/71
Proof test procedures:• wet test in application • test in reference tank
Test interval: ≤ 5 years
DCS-System
x
Electronic insertsFEL 51(2 wire AC)FEL 52(3 wire DC)FEL 54(AC/DC+Relay)FEL 55 (8/16 mA)
Slide 46 RV / GJ
PTC = Proof Test Coverage
02/20/2015
Proof-testing PFM-Electronic FEL 57 + FTL 325P
2-wire, intrinsically safeLiquiphant FTL 50/51/70/71
empty :
full :
Fault :
50 Hz
150 Hz
0 Hz
• 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
Nivotester FTL 325 P
Slide 47 RV / GJ
02/20/2015
Liquid Bulk StorageIndependent 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 RV / GJ
02/20/2015
WHG
RMA422
RMA422
FTL325PSIL 2
SIL 2/3
Tankvision Scanner
IEC 61511 SIS loop
Limit Hi
Display
Fill Limit
Display
Limit HiHi
Display
Level, Temperature,
Volume, Pressure,
Alarms, …
• Ethernet TCP
Operator Limit
A
Logic Solver
OPC
Level limit
• PFM
• DO
• Namur
Level
• 4-20mA
Level Limit
• DO
SIL 2 SIL 2
Level Limit
• DO
Level, Temperature,
Pressure …
• Modbus
• V1
• others
Level,…
• 4-20mA
Limit B
• DO
Level
• 4-20mA
Limit A
• DO
Level Limit
• DO
PLC
Operator Limit
n
Inventory System
…
Other values required
For Operator
• Ethernet OPC
SIS Logic
Limit HiHi
• DO
•Ethernet OPC
Overfill Prevention
Tank Inventory Measurem
ent
HMI
Separate overfill prevention from the tank gauging system…
API 2350
Slide 49 RV / GJ
02/20/2015
Products Solutions Services
Reliable. Safe. Cost Effective.
The Innovative OfferingElectronic dp for Level Measurement - Deltabar FMD71/72
Slide 53 RV / GJ
02/20/2015
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
• Proven established technology utilized in a new innovative way:
• 2 sensors• 1 transmitter • 1 signal output to control systemStart by click the animation
Slide 54 RV / GJ
02/20/2015
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 RV / GJ
02/20/2015
Eliminate measurement drift up to 95%
Performance (offset capillary)
± 4.5% 8.58in (218mm)
Total performance
± 0.23% ± 0.72in (18mm)
No influence from varying ambient
conditions!!!
Eliminate measurement drift due to ambient temperature changes up to 95% with Deltabar
FMD72 electronic dp!
Capillary systemElectronic dp
LP
HP
2.9 psi/
200mbar
26ft
(7.9
m)
26ft
(7.9
m)
2.9 psi/
200mbarmax.
min.
160°F
(70°C)
+77°F
(25°C)
FMD78FMD72
Slide 56 RV / GJ
02/20/2015
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 RV / GJ
02/20/2015
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 ambient temperature of low pressure side of capillary (top side of the tank)
Get the automatic calculated offset of the diaphragm
Enter capillary length
Slide 58 RV / GJ
02/20/2015
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
Choose automatic sensor selection to get the process optimized sensor ranges
Automatic calculated measuring performance
Slide 59 RV / GJ
02/20/2015
Spare Concept of Deltabar FMD72 electronic dp
Replacement just of the cable
Time of replacement:
30 min.
Replacement of the whole capillary system
necessary
Time of replacement (in case the right
system is on stock):
5 hours
Spare part needed:
Spare part needed:
3’000 US$
300 US$
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.
min. +
Slide 60 RV / GJ
02/20/2015
Eliminate Plugging of Impulse Lines to Increase Safety
Mechanical dp measurement using impulse lines
Plugging due to crystallizing media nitrogen purging
Plugging by iced media heating of impulse lines
High maintenance effort
Eliminate these issues with electronic dP:
Maintenance-free
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.
impulse line
h
hb
g
phead
T
hc
pc
plugged
lines
Slide 61 RV / GJ
02/20/2015
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 RV / GJ
02/20/2015
Suitable Housings for Each Application
Stainless steel and aluminum housings available
Highest flexibility in material selection
Depending on ambient conditions, material of sensor modules and transmitters could be
varied
Ensured durability of materials reduces maintenance efforts and ensures a reliable and safe
process
Slide 72 RV / GJ
02/20/2015
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
-40…80°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 RV / GJ
02/20/2015
Continuous Health Indication for Doubtless Reliability
FMD7x offers worthy information to save costs and lots of time in your plant maintenance
TC
TT
DT PT
Q
OilHeater Boiler with
waste solvent
Distillation Column
Device Diagnostics Electronic diagnostics Temperature values Pressure bumps Valid configuration diagnostics
Loop diagnostics Level loop diagnostics Measurement loop diagnostics Cascade loop diagnostics Fieldbus communication
diagnostics
Process diagnostics Variability index Statistical process monitoring Process performance index Pump diagnostics
FMD7x – a perfect basis
for more sophisticated
diagnostic coverage
in your plant
Slide 75 RV / GJ
02/20/2015
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 RV / GJ
02/20/2015
Questions ?
Slide 77 RV / GJ
02/20/2015
More information on our web site
http://www.ca.endress.com/en
Slide 78 RV / GJ
02/20/2015
Thank you for your attention
Gerhard Jansson
gerhard.jansson@ca.endress.com
Slide 79 RV / GJ