Presentation on theme: "Rosemount 3051S Electronic Remote Sensors A Digital Upgrade to a Proven Technology."— Presentation transcript:
Rosemount 3051S Electronic Remote Sensors A Digital Upgrade to a Proven Technology
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 2 Slide 2 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 Leg Tuned-System Balanced System DP 30% Process Level Market by Technology * Radar 17% Ultrasonic 12% Other 26% 3051S ERS Switches 15% *VDC Global Process Level (2005), ARC Global Radar Study (2008), F&S Global Level Sensors (2005)
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 3 Slide 3 New 3051S Electronic Remote Sensors Enhance DP Level Technology Wire 4-20 mA DP = P HI – P LO P HI P LO 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 Confidential 27-Jun-01, Slide 4 Slide S 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 = P HI – P LO P HI P LO
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 5 Slide S ERS Architecture Supports Flexible Installations 3051S ERS Simplifies Installation Practices 3051SAL with Featureboard 3051SAL Remote Display with Featureboard 3051SAM with level flanges 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 Confidential 27-Jun-01, Slide 6 Slide S 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 Evaporation Wet LegDry Leg Condensation Fill Fluid Density & Volume Changes with Temperature Capillary3051S ERS System Electrical Wire Digital architecture eliminates temperature effects
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 7 Slide S 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 Confidential 27-Jun-01, Slide 8 Slide S ERS Provides Greater Insight Into Your Process Automatic & synchronized DP calculation Monitor P HI and P LO pressures in real-time Scaled Variable converts DP into level & volume measurements Process alerts enable proactive maintenance practices
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 9 Slide 9 20-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 Confidential 27-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 Solution P2P2 P1P1 P1P1 P2P2 DP ∆P DP ∆P P LO P HI 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 Confidential 27-Jun-01, Slide 11 Slide 11 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 Confidential 27-Jun-01, Slide 12 Slide 12 Oil 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 Confidential 27-Jun-01, Slide 13 Slide 13 Austrian 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 Application Level 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 Confidential 27-Jun-01, Slide 14 Slide 14 Pulp 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 Application Vacuum 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 Confidential 27-Jun-01, Slide 15 Slide 15 Biotech 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 Application Level 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 Confidential 27-Jun-01, Slide 16 Slide 16 Solvay 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 Confidential 27-Jun-01, Slide 17 Slide 17 Chemical 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 Application 20 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 Confidential 27-Jun-01, Slide 18 Slide 18 Silicon 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 Application Level 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 Confidential 27-Jun-01, Slide 19 Slide S ERS System Proven ERS Applications 1.Distillation Tower 2.Chemical Holding Tank 3.Enzyme Fermentation 4.Batch Tank 5.Vacuum Tank 6.Chemical Reactor 7.Black Liquor Level 8.Beer Storage 9.Glycerin Refining 10.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 Successes
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 20 Slide S ERS Compliments Traditional DP Level Technology 100 in.H psi Tuned-System™ Assembly Sensor sized on DP column only DP Sensor Span = 100 in.H 2 0 Electronic Remote Sensors Sensors sized on amount of static pressure + DP column GP Sensor Span = psi (2868 in.H 2 0) 100 PSI 100 in.H 2 0 High Pressure Application Example ERSTuned-System ±2.8 in.H 2 0 ±1.4 in.H F Ambient Temperature Change VS
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 21 Slide 21 Traditional 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 Confidential 27-Jun-01, Slide 22 Slide 22 Achieve Success with Rosemount DP Level in More Places than Ever Before