next level instrumentation - primary target...

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

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Heartbeat Technology™ - elements

Heartbeat Verification

Heartbeat Diagnostics

Heartbeat Monitoring• ------------------• ------------------• ------------------• ------------------• ------------------

Pass / Fail

Heartbeat Technology™

Slide 3 RV / GJ

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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)


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

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Animation HistoROM


Slide 13 RV / GJ

02/20/2015

HistoROM

Electronic change during night shift


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


Micropilot FMR5x – Next Level Instrumentation

Slide 15 RV / GJ

02/20/2015

Extended HistoROM – Event List – up 100 events


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


Slide 17 RV / GJ

02/20/2015

Extended HistoROM - Statistics

• Statistical information about recorded values


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


Slide 19 RV / GJ

02/20/2015

Process monitoring – the “Heart beat” of your process

Build up on an antenna(explained on a Micropilot)


Slide 20 RV / GJ

02/20/2015


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


Firefighters fight flames at the BP plant in Texas City after the July 28, 2005 explosion. (15 dead & 170 injured)


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


Example – Level Continuous

Guided Wave Radar Levelflex FMP 5x


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


Example - Level switch

Tuning fork switch Liquiphant FTL5x, FTL7x Liquiphant Failsafe


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


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

[email protected]

Slide 79 RV / GJ

next level instrumentation - primary target...

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