next level instrumentation - primary target...

02/20/2015

Products Solutions Services

Canadian Tech days

Next Level Instrumentation

By Ing. Rob Vermeulen, Bec

Slide 1

02/20/2015

Why do we need to go to the next level….?

RVSlide 2

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.

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Heartbeat Technology™ - elements

Heartbeat Technology

Heartbeat Verification

Heartbeat Diagnostics

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

Pass / Fail

Heartbeat Technology™

Slide 3 Rob Vermeulen

02/20/2015

Heartbeat Technology

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

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Onboard diagnostics – running in the backgroundMicropilot FMR5x – Next Level Instrumentation

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

02/20/2015

Measurement signal Verification – Multi Echo Tracking

Micropilot FMR5x – Next Level Instrumentation

Animation to describe the Multi-Echo Tracking(explained on a Micropilot)

Start by click the animation

Slide 6 RV

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)

Slide 7 RV

We give you more than a mere measured value.…

02/20/2015

Process monitoring – the “Heart beat” of your process


Animation of foam measurement(explained on a Micropilot)


Slide 8 RV

02/20/2015

Process monitoring – the “Heart beat” of your process


Build up on an antenna(explained on a Micropilot)


Slide 9 RV

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


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


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


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


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Animation HistoROM




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HistoROM


Electronic change during night shift


Example HistoROM functionality


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Extended HistoROM

• Coming free of charge with• Levelflex HART (SW 1.02.00)

• PA & FF follow later this year

• 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


Slide 16 MTF/STJ


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Extended HistoROM – Event List – up 100 events

Slide 17 MTF/STJ


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Extended HistoROM - Trend

• Visualization of up to 4 trend values• Visualization of events in correlation with trend values

Slide 18 MTF/STJ


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Extended HistoROM - Statistics

• Statistical information about recorded values

Slide 19 MTF/STJ


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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 20 MTF/STJ


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Proof testing…. Necessary, Safe and Practical.


Slide 21

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FMR5x series

And now something completely different…..

RVSlide 22

• Please stand up and introduce yourself to the person on the right of you.

• Small introduction of how a Dutch guy sees Canada.

02/20/2015

How does a Dutch guy see Canada and it’s inhabitants?

RVSlide 23

Practical

Sporty peoplemodest

Multi culti

Have humorSnow

02/20/2015


Proof testing…. Necessary, Safe and Practical.


Slide 24

02/20/2015Slide 25 / 49

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…….

02/20/2015 Volker SchulzSlide 26 / 49


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


02/20/2015

Setting The Pace For Tank Safety!

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 reports

02/20/2015Slide 28 / 49

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

02/20/2015

So what can help prevent this in future? Overfill Prevention Cabinets according to API 2350

02/20/2015Slide 30 / 49

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

02/20/2015Slide 31 / 49

Proof Testing for bulk liquid storage tanks

Fig. a. storage tank with conical roof Fig. b. storage tank with external floating roof

Fig. c. storage tank with internal floating roof

Fig. d. storage tank with (external) floating roof and (retrofit) dome roof

Possibilities are determined by tank constructions

Simple Rules Still Apply

02/20/2015Slide 32 / 49

Fixed Roof – SAFE LAHH Solutions

Liquiphant – Vibronics, Tuning Fork Measurement of aggregation phase by fluid density, Gas versus LiquidLevelflex – Guided Wave Radar, Time Domain ReflectometryMeasurement of true level using dielectric reflection at phase change

02/20/2015 Volker SchulzSlide 33 / 49

Proof testing

• Push button activated test

generator (annual)

• High proof test coverage

• By expert inspection

• Proof test coverage depends on

inspection depth

MountingFunctional Safety

• IEC 61508 design• Proven in use• Suitable for SIL 2 / 3 (3 when used in

homogeneous redundancy)

• Switching in remote switch unit• Discrete output (relays)

• 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

Liquiphant

Guided Wave Radar (TDR)

Side Top

Top adjustable

Top

02/20/2015Slide 34 / 49

Liquid Bulk StorageIndependent High Level Alarms – Best technology Available

Liquiphant is always the first solution.

Internal Floating Roofs and External Decks do require stilling wells or side mounted nozzles to be installed.

02/20/2015

Volker SchulzSlide 35 / 49

Guided radar as over spill protectionLevelflex as SIL 2 overspill protection on Fixed roof tanks and LPG bullets

02/20/2015Slide 36 / 49

Floating Roof – SAFE LAHH Solutions(Liquiphant – Stilling well mounting is always preferred)Micropilot – Free Field Radar, Time of FlightMeasurement of roof level using dielectric reflection at phase change Liquicap – Capacitance type contact switchingMeasurement of dielectric impedance change by roof contact

02/20/2015

Damaged deck

• May lead to lost and deflected

echo depending on deck position

• Fails Safe

• Switch level may raise

depending on deck position

• May fail when deck gets over

flooded

Lost deck

• May lead to some switch point

deviation (up to 100 mm)

• No failure

• May lead to severe switch point

deviation

• Fails dangerous

• May become safe when weight

is modified

Snow cover

• May lead to lost echo

• Fails Safe

• Availability increased using

new Advanced Dynamics design

• Top of snow detected as raised

level

• No Failure

(external) floating roof failure scenarios

Free space Radar

Capacitancetype

02/20/2015 Volker Schulz

Floating Roof TanksIndependent High Level Alarms / Radar – Proof Testing external

External Swivel plate for functional

proof testing

Combined Swivel plate for functional

proof testing

02/20/2015 Volker chulzSlide 39 / 49

Secure Switch Settings using Contact Plate

next level instrumentation - primary target...

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