Presentation on theme: "Rosemount 3051S Electronic Remote Sensors"— Presentation transcript:
1 Rosemount 3051S Electronic Remote Sensors A Digital Upgrade to a Proven Technology
2 DP Level is a Proven and Successful Technology Process Level Marketby Technology*Other26%DP 30%Straightforward measurement techniqueEasily verified and calibratedFlexibility enables use in variety of applications (mass, density, interface)Ultrasonic12%Radar17%Switches15%3051S ERSTuned-SystemBalanced SystemWet LegDry LegNEW*VDC Global Process Level (2005), ARC Global Radar Study (2008), F&S Global Level Sensors (2005)2
3 New 3051S Electronic Remote Sensors Enhance DP Level Technology PLODP Calculated ElectronicallyTwo Pressure SensorsElectronics FeatureboardWireUtilizes Proven 3051S Sensor PlatformDP = PHI – PLO4-20 mATwo-Wire 4-20 mA Output with HARTPHI
4 3051S ERS Provides Additional DP Level Capabilities Simplified InstallationsPLOImproved PerformanceWireSimplified Maintenance & Spares InventoryDP = PHI – PLO4-20 mAAccess to New InformationPHISynchronized & Integrated Solution
5 3051S ERS Simplifies Installation Practices 1. Independently install each sensorDirect-mount without pipe stand, brackets, and other hardwareCan be installed by a single instrument tech12. Wire sensors togetherNon-proprietary electrical wireEasy to install around catwalks, on distillation columns, etc.Eliminate insulation and heat tracing23. Perform a system zero trimEstablishes true zero-based DP measurementNo zero elevation calculation required133051S ERS Architecture Supports Flexible Installations3051SAM3051SAM with FeatureboardRemote Display with Featureboard3051SAM with level flanges3051SAL with Featureboard3051SAL5
6 3051S ERS Digital Architecture Delivers Improved Performance Direct Connection to Tank Reduces Time Response Digital Architecture Eliminates Measurement Drift2.5 sec.0.5 sec.Transmitter with10 ft (3 m) CapillaryDirect-Mounted ERS TransmitterWet LegDry LegCapillary3051S ERS SystemEvaporationElectrical WireCondensationFill Fluid Density & Volume Changes with TemperatureDigital architecture eliminates temperature effects
7 3051S ERS Simplifies Maintenance and Spares Inventory Replace one transmitter vs. entire capillary assemblySimplify spares inventory & standardize on common ERS componentsXCorrosionProcess-coated diaphragmHydrogen permeation7
8 3051S ERS Provides Greater Insight Into Your Process Automatic & synchronized DP calculationMonitor PHI and PLO pressures in real-timeProcess alerts enable proactive maintenance practicesScaled Variable converts DP into level & volume measurements
9 20-Point Scaled Variable Simplifies Configuration & Commissioning Automatically convert DP into level, volume, mass, or other variables3 Easy Configuration Options1DirectManually provide up to 20 “DP vs. Scaled” pairings25 mbar = 17.9LITER2Tank FormulasScaled Variable using basic tank dimensions3Strapping TableScaled Variable using tank strapping table
10 3051S ERS Provides an Easy, Integrated Solution Do-it-Yourself (Two Transmitters)3051S ERSPLOP2P1∆P∆PP2No error from change in static pressure (∆P)DPDPP1PHINot synchronized2x wiring costs2x required I/ODCS programmingDifficult to “zero” DPSynchronized measurementsSingle 2-wire 4-20mA loopNo DCS programmingEasily zeroed & calibrated
11 Chevron Phillips Chemical (Borger, TX) Achieved Success with 3051S ERS CHALLENGEBridle with magnetic float and unreliable heat tracingFalse level measurement & unplanned shutdownsSOLUTION3051S ERS easily retrofitted entire bridle assemblyDigital architecture eliminated need for heat tracingRESULTSNo unplanned shutdowns since installation of 3051S ERS (3+ years)Application30 ft (9 m) process storage tankAmbient Temp0 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
12 Oil Refinery Eliminates Unplanned Shutdowns on Reactor with 3051S ERS CHALLENGEFrequent, unplanned plant shutdownsCaused by plugged lines on pneumatic transmitter with wet legSOLUTION3051S ERS assembly with FFWflush flanged sealsRESULTS100% measurement reliability since installation (3+ years)No work orders or requests for troubleshootingApplicationAlkylation reactorLevel measurement of effluent liquidThe 3051S ERS assembly with flanged seals was easily retrofitted on the Alkylation reactor and eliminated unplanned process shutdowns.
13 Austrian Pulp and Paper Mill Decreases Maintenance Costs with ERS Technology CHALLENGEExcessive maintenance costs on wet leg installationPlugged linesHeat tracingVacuum spikesSuboptimal black liquor outputSOLUTION3051S ERS systemRESULTSElimination of heat tracing and water purgingIncreased reliability and repeatability of level measurementApplicationLevel measurement on black liquor vesselZellstoff Pöls Austria was able to address reoccurring maintenance problems and improve their level measurement by upgrading to a 3051S ERS system.
14 Pulp and Paper Mill Reduces Downtime with Digital 3051S ERS Architecture CHALLENGEApprox. one unplanned shutdown per monthPump cavitationsReoccurring problems with wet legsPlugged impulse linesMaintaining level in wet legSOLUTION3051S ERS systemRESULTSElimination of wet legOnly one shutdown over 2-year periodProcess runs in automatic close to 100% of timeApplicationVacuum 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”
15 Biotech Facility Increases Throughput on Fermentation Vessel with 3051S ERS CHALLENGEInconsistent batches3-5% measurement errorUnable to calculate yieldSOLUTION3051S ERS system with hygienic Tank-Spud sealsRESULTSMeasurement error improved to less than < 0.5%Drastic time response improvementAchieved consistent, high-quality batchesApplicationLevel 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.”
16 Solvay Decreases Operations & Maintenance Costs with 3051S ERS CHALLENGECosts and challenges associated with DP transmitter and wet leg installationSalt crystals would plug impulse linesRequired complicated water injection systemEvaporator had to be taken off line frequentlySOLUTION3051S ERS with EFW extended diaphragm sealRESULTSExtended seal used at bottom of tank eliminated pluggingDigital architecture enabled optimized controlApplicationBrine level measurement33 ft (10 m) evaporator“The ERS system has been installed for months, much to our total satisfaction”- Jean-Marc Deconto, Solvay engineer
17 Chemical Company Eliminates Excessive Maintenance Costs with 3051S ERS CHALLENGEExcessive maintenance costs:Troubleshooting dry leg installationDaily field visits to check distillation packingMeasurement drift from temperature variationsSOLUTION3051S ERS systemRESULTSNo unplanned shutdowns for over one yearAble to accurately monitor health of packing in tower without manual trips to fieldEliminated costs associated with troubleshooting installationApplication20 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
18 Silicon Manufacturer Reduces Inventory Costs with 3051S ERS CHALLENGEExcessive capillary caused measurement error > 5%Inconsistent batchesMaterial shortagesHigh scrap ratesSOLUTION3051S ERS systemRESULTSAccurate level measurementAchieved consistent batchesNo unplanned shutdownsApplicationLevel control in silicon holding tankThe long lengths of capillary with the previous installation were completely eliminated with the digital architecture of the 3051S ERS system.
20 3051S ERS Compliments Traditional DP Level Technology Electronic Remote SensorsSensors sized on amount of static pressure + DP columnGP Sensor Span = psi(2868 in.H20)100 PSI100 psiTuned-System™ AssemblySensor sized on DP column onlyDP Sensor Span = 100 in.H20100 in.H20100 in.H20High Pressure Application ExampleERS Tuned-System±2.8 in.H20 ±1.4 in.H2025 F Ambient Temperature ChangeVS
21 Traditional DP Level Technologies Still Have Key Applications and Benefits Tuned-System AssemblyBalanced Capillary SystemDP transmitter with wet legDP transmitter with dry legApplication CharacteristicsShort SpansHigh PressuresIndoor VesselsStable TemperaturesSimple InstallationsWirelessTuned-SystemAssembly
22 Achieve Success with Rosemount DP Level in More Places than Ever Before BalancedSystem3051S ERSTuned-SystemWet LegDry LegMeasurementsPressureLevelVolumeInterfaceDensityMassFlowApplicationsHot & cold temperaturesCorrosive & viscous processesVacuumsFoam, agitation, & other tank disturbancesVessels & towersIndustriesRefiningPulp and paperOil & gasChemicalFood and beverageBiotechnology