Use your instrumentation – the right way - dau.dkdau.dk/Content/file_knowledge_item/Dau_EH_1_96_INT.pdf · Use your instrumentation – the right way ... Proof procedure via manual

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06/12/2013

Use your instrumentation – the right way

Your instruments are already looking out! When are you ready to open the window?

Slide 1 Kasper Adsersen


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Secondary values from your instrumentation

Next Level Instrumentation


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Micropilot/Levelflex product family

Use your instrumentation - the right way

• Dynamic algorithms• Multi-Echo Tracking• Accuracy ±2mm

• Intuitive operating concept• HistoROM – data management• Seamless system integration • Exact instrument and process

diagnosis

Safe Precise Efficient• Hardware and software

developed according to IEC 61508, SIL2 for single device and SIL3 in homogenous redundancy

• High temperature and high pressure versions

• Gastight feedthrough as second line of defense


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Development according to IEC 61508


• The new ToF Series FMR/FMP5x are the world’s first ToF devices which has been developed according to IEC 61508:2010 (Edition 2.0)

• All FMR/FMP5x are suitable for the use in safety-loops (MIN, MAX and RANGE) with all 4…20mA HART® options, up to

• SIL3 (in homogenous redundancy)• SIL2 (as a single device)

• For test sequence C (simulation) it is not necessary to interrupted or manipulated the production process and can be done easily from control room (Communication between device and DTM is secured)

• Development supported by certified TÜV Functional Safety Engineers and TÜV Functional Safety Expert

• Independent Functional Safety Assessment and certification by accredited body (TÜV Rheinland)


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Developed according IEC61508


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


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Proof test from control room


Proof procedure via manual started self check (proof test)

Proof test is done without interruption of the process!

Send

Check

Save time and costs with worlds easiest proof test for SIL/WHG1. Start the “Self check” (device checks internal communication

path)2. Check the signal output by simply starting the simulation

Developed acc. to IEC61508, also the data communication between Device-DTM and device is secured (send – check). The proof test can easily done out of the control room


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Setup FieldCare DTM


Same user oriented menu structure like on-site displayUser role is per default: Maintenance FieldCare Device Setup delivered with device


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What is Advanced Diagnostics ?


• Advanced Diagnostics in Micropilot/Levelflex, offers additional possibilities to monitor the process

• The Micropilot/Levelflex offers two advanced diagnostics, which can be used stand alone or can be linked together

• Choose different inputs like:• Level linearized, Unfiltered distance, Rel. Echo Amplitude,

• Area of In-coupling of HF-Cable, Electronic Temp., Terminal voltage

• The Advanced Diagnostics can use different statistic functions with the chosen input value like:

• Maximum, Minimum, Mean, Standard deviation

• Difference Max. – Min., Slope

• These calculated values can be monitored in the DCS/PLC´s or used as a switch output, second mA output or to link this information to the second advanced diagnostics in the Micropilot/Levelflex



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Wastewater treatment / biogas production

Digester optimizationIncrease the gas production – save money – less cleaning


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How does it work ? Foam detection 1/4


• Problem:

• The digester can “produce” foam from time to time.Depend on the season and chemical/protein leftover in the wastewater received.

• While the digestion process runs, foam can occur. This foam can create big problems, because foam in the piping/venting system needs maintenance work to clean the process equipment

• The foam can be avoided by sprinkling water from the top or by adding a chemical foam inhibitor to the mixture.This solution however is costly and could also reduce the efficiency of the digester and result in lower gas production

• Pre Conditions:

• The process can be monitored with and without foam during commissioning


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• What happens with the Micropilot signal if foam occurs ?

• The rel. echo amplitude will decrease and this can be used to run a “foam” detection with the Advanced Diagnostic function

• The raw value of the rel. echo amplitude can be appointed to one of the secondary HART® values and used in the control system.

• Or: a function block in the Micropilot is set up to output the value on the second mA output

• Or: the digital status output is used as a simple foam yes or no signal

• If the foam level is very high, the signal will be lost - like all other radars on the market. This is simply a physical limit of the measuring principle.BUT when using the function, the foam formation can be stopped beforereaching a level critical for the measurement


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Defined echo amplitude limit


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What has to be done ?• The signal has to be observed for a while. The echo amplitude in the process at

e.g. 80% level (via output or the drag indicators of the advanced diagnostics of FMR5x). After this, you define the lower limit of the amplitude.

• Program the advanced diagnostics blocks 1 and 2 to detect foam

Advanced Diagnostic 1

(4) – (7)

(11) / (12)

Alarm handling

Calculation

Advanced Diagnostic 1(AD1)

Upper limit: 85%Lower limit: 75%

Check mode: In range

Assign diagnostic

signal:Level (%)

AD1 digitaloutput

Level (%)

Advanced Diagnostic 2 (AD2)

Linking logic AD2:And

Link AD2 to:Digital out AD1

Assigndiagnostic

signal:Echo amplitude

AD digitaloutput

AD analogoutput

Sample time: 60 sec

Calculation type: Mean

Check mode: Lower limitLower limit: 10dB

Status output and programmableWarning/Alarm event

Echo amplitude (dB)



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Proline Prosonic Flow B 200

Online Methane measurement as a secondary valueThe primary value is the volume flow


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100% CH4 @ 40 °C


Temperature Methane Carbon dioxide

Speed of sound

°C CH4 CO2 m/s

40 0.0% 100.0% 274.7

40 10.0% 90.0% 284.1

40 20.0% 80.0% 294.5

40 30.0% 70.0% 306.0

40 40.0% 60.0% 319.0

40 50.0% 50.0% 333.8

40 60.0% 40.0% 350.8

40 70.0% 30.0% 370.7

40 80.0% 20.0% 394.2

40 90.0% 10.0% 422.8

40 100.0% 0.0% 458.5

The speed of sound in 100% Methane at 40 °C is 458.5 m/s


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Biogas 60% CH4 40% CO2 @ 40 °C


Temperature Methane Carbon dioxide

Speed of sound

°C CH4 CO2 m/s

40 0.0% 100.0% 274.7

40 10.0% 90.0% 284.1

40 20.0% 80.0% 294.5

40 30.0% 70.0% 306.0

40 40.0% 60.0% 319.0

40 50.0% 50.0% 333.8

40 60.0% 40.0% 350.8

40 70.0% 30.0% 370.7

40 80.0% 20.0% 394.2

40 90.0% 10.0% 422.8

40 100.0% 0.0% 458.5

The speed of sound in biogas (60% CH4 40% CO2) at 40 °C is 350.8 m/s



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A global view

HART® and other communication protocols used in instrumentation


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European Fieldbus Market Market Information

Competition

Key Success Factors

Well established communication protocol

Approx. 37 mill. installed devices with HART® communication

Market still shows a good growth but mainly based on MRO business

All established competitors in the process automation have devices with HART® communication

Display of all four HART® values (PV, SV, TV, QV) of one sensor

Request for HART 7 devices is increasing

Cost-effective price

Market distribution of fieldbuses

Source: Frost & Sullivan, European Fieldbus Market, 2009

Also in the U.S. and Asia HART® is a well established communication standard and makes up more than 50%

of the market

Market Information – HART® Communication


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Industry segmentation of HART® devices in Europe

Source: Frost & Sullivan, European Fieldbus Market, 2009

Market Information – HART® Communication


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•Endress+Hauser had a turnover of approx. 750 mill. € with HART® devices in 2012

•This complies with a number of approx. 550,000 sold units

•The HART® devices were sold in all Industry segment but with the biggest share in the Chemical and Oil & Gas industries

• An indicator that supports HART® communication can be used with a huge number of already installed units

• Process indicator RIA15 with HART® supports the global trend of using HART® values for getting more process information and not only using the protocol for the parameterization/commissioning

Facts and Figures


History – HART® Products of Endress+Hauser



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No HART® transparency to your control system ?No problem!Loop Powered Indicator RIA15 with HART® Communication


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Flexibility: With RIA15 4…20 mA or HART® communication is possibleLittle requirements: Very low voltage drop of ≤ 1.9 V with HART® makes an additional power supply unnecessaryUp to four values: RIA15 can indicate all four values (PV, SV, TV, QV) of one sensor in the analog HART® mode as well as in a multi-drop networkMaster functionality:RIA15 can be primary or secondary master and actively inquire values from the sensorAll information at a glance: RIA15 can indicate the values in alternation incl. bar graph and engineering unitExcellent readability: Very large characters with a height of 17 mm (0.67 in) and an optional backlight guarantee a good readability in all lighting conditions

Summary of main features and advantages


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• RIA15 fulfills the requirements of HCF Specification, revision 7.x

• RIA15 is downwards compatible to all sensors/actuators with HART® versions 5.x, 6.x as well as 7.x

RIA15 can be used with HART® instrumentation/sensors/actuators of the newest generation

Due to downwards compatibility thereis a large installed base of devices with which RIA15 can be applied


Key feature: Compatibility

NEW Feature HART® Communication


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More process information


More process informationmass, volume, corrected

volume, density, ref. density, temperature.


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Wireless HART® features


Local Wireless Network:• Full mesh (or star)• Self-organizing• Self-healing• Redundant routing• Time synchronized, i.e.

power efficient• Coexist w/ WLAN, etc.• 128-bit encryption

An additional accessories is the WirelessHART® adapter SWA70. It opens the world to the wireless communication and to various customer benefits.


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• More than 40 variables are available to be displayed

• When using the Advanced Diagnostics and FieldCare, the condition of the flowmeter can be monitored in details.

• Endress+Hauser can even output the viscosity of the media. Viscosity is often use to control heating of a media in blending and combustion processes

• Typically installation: mA output is used for Mass flow pulse/freq. output is used for the totalizer

• What about: density of the media, temperature in the pipe, air in the pipe, corrosion inside the meter… no value for you???


A Coriolis flow meter measures a lot of relevant data


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How to get the relevant value out of your Promass



Description available in the standard manual

Just select the relevant value To be displayed as:PV, SV, TV or QV – that´s it!!!

No options need to be orderedEverything is standard

No extra price

Similar possibilities with Profibus and Foundation Fieldbus

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Just 5 additional ideas – we have a lot more for you!


1. Compare your internal temperature in your flowmeter with the process temperature

Rising difference = someone need to check the two devices

2. Compare the electronic temperature with the room temperature – verify that it is still working.

Rising difference = someone need to check the two devices

Temperature > 60-70 deg. C = activate ventilation/cooling or send someone to observe

3. Monitor the supply voltage to keep track of your power supply and cabling/installation

Humidity in connection boxes will be detected – before you loose the measurement

4. Monitor the near-field signal to detect build-up and condensation in the top of the tank.

Build-up could reduce the quality/safety of the level measurement – reduce the agitator speed

5. Monitor the abs. echo amplitude to detect build-up on the tank wall

When should the tank cleaning be performed – no need to open a clean tank


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Using your instrumentation – the right way


Kasper AdsersenSlide 29

1. Can increase your product quality

Better competitiveness – DKK € $

2. Can reduce down time

Higher production rate – DKK € $

3. Can reduce production loss

Higher production – DKK € $

Less waste = better image and less expenses on waste handling

4. Can increase the plant safety

Higher safety = better image and maybe lower insurance rates (SIL)

5. Can save foam inhibitors and chemicals used for cleaning

Less chemicals used = saved DKK € $ + better image


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Thank you very much for your attention

Using your instrumentation – the right way

Is a true contribution to the improvement of our competitiveness in Denmark

But: We are NOT ahead of other countries here – we are behind at the moment


Documents

Use your instrumentation – the right way - dau.dkdau.dk/Content/file_knowledge_item/Dau_EH_1_96_INT.pdf · Use your instrumentation – the right way ... Proof procedure via manual