rosemount 3051s electronic remote sensors

Rosemount 3051SElectronic Remote SensorsA Digital Upgrade to a Proven Technology

[File Name or Event]Emerson Confidential27-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 LegTuned-System Balanced System

DP 30%

Process Level Market by Technology*

Radar17%

Ultrasonic12%

Other26%

3051S ERS

NEW

GravitySpecific PressureLevel

Switches15%

*VDC Global Process Level (2005), ARC Global Radar Study (2008), F&S Global Level Sensors (2005)


Slide 3

New 3051S Electronic Remote Sensors Enhance DP Level Technology

Wire

4-20 mA

DP = PHI – PLO

PHI

PLO DP Calculated Electronically• Two Pressure Sensors• Electronics Featureboard

Utilizes Proven 3051S Sensor Platform

Two-Wire 4-20 mA Output with HART


Slide 4

3051S 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 = PHI – PLO

PHI

PLO


Slide 5

3051S ERS Architecture Supports Flexible Installations

3051S ERS Simplifies Installation Practices

3051SAL with Featureboard

3051SAL

Remote Display with Featureboard 3051SAM with

level flanges

1

1

2

33. 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


Slide 6

3051S ERS Digital Architecture Delivers Improved PerformanceDirect Connection to Tank Reduces Time Response

Digital Architecture Eliminates Measurement DriftDirect-Mounted ERS Transmitter

Transmitter with 10 ft (3 m) Capillary

0.5 sec.2.5 sec.

Evaporation

Wet Leg Dry Leg

Condensation

Fill Fluid Density & Volume Changes with

Temperature

Capillary 3051S ERS System

Electrical Wire

Digital architecture eliminates temperature

effects


Slide 7

3051S 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


Slide 8

System DP

20.23 psi

P-Hi Pressure

70.89 psi

50.66 psi

P-Lo Pressure Scaled Variable

0

100

200300

400

500

600

153.84 GALNS

P-Hi Module Temperature

P-Lo Module Temperature

-50 200

-8.33

33.3375

116.67

158.33

-50 200

-8.33

33.3375

116.67

158.33

105.5 deg.F

82.8 deg.F

3051S ERS Provides Greater Insight Into Your Process

Automatic & synchronized DP calculation

Monitor PHI and PLO pressures in real-time

System DP

20.23 psi

P-Hi Pressure

70.89 psi

50.66 psi


0

100

200300

400

500

600

153. 84 GALNS


P-Lo Module Temp erature

-50 200

-8.33

33.3375

116 .67

158.33

-50 200

-8.33

33.3375

116.67

158.33

105.5 deg .F

82.8 deg.F

System DP

20.23 psi

P-Hi Pressure

70.89 psi

50.66 psi


0

100

200300

400

500

600

153.84 GALNS



-50 200

-8.33

33.3375

116.67

158.33

-50 200

-8.33

33.3375

116.67

158.33

105.5 deg.F

82.8 deg.F

System DP

20.23 psi

P-Hi Pressure

70.89 psi

50.66 psi


0

100

200300

400

500

600

153.84 GALNS



-50 200

-8.33

33.3375

116.67

158.33

-50 200

-8.33

33.3375

116.67

158.33

105.5 deg.F

82.8 deg.F

Scaled Variable converts DP into level & volume measurements

Process alerts enable proactive maintenance practices


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


Slide 10

• Not synchronized• 2x wiring costs• 2x required I/O• DCS programming• Difficult to “zero” DP

3051S ERS Provides an Easy, Integrated Solution

P2

P1

P1

P2

DP

∆P

DP

∆P

PLO

PHI

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)


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


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.


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

ApplicationLevel 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.


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

ApplicationVacuum 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”


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

ApplicationLevel 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.”


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 controlApplication• 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


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

Application20 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


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

ApplicationLevel 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.


Slide 19

3051S ERS

System

Proven ERS Applications1. Distillation Tower2. Chemical Holding Tank3. Enzyme Fermentation4. Batch Tank5. Vacuum Tank6. Chemical Reactor7. Black Liquor Level8. Beer Storage9. Glycerin Refining10. 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


Slide 20

3051S ERS Compliments Traditional DP Level Technology

100 in.H20

100 psi

Tuned-System™ Assembly• Sensor sized on DP column only • DP Sensor Span = 100 in.H20

Electronic Remote Sensors• Sensors sized on amount of static

pressure + DP column• GP Sensor Span = 103.6 psi

(2868 in.H20)

100 PSI

100 in.H20

High Pressure Application ExampleERS

Tuned-System±2.8 in.H20

±1.4 in.H20

25 F Ambient Temperature Change

VS


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


Slide 22

Achieve Success with Rosemount DP Level in More Places than Ever Before

Wet Leg Dry LegTuned-SystemBalanced System3051S ERS

Measurements• Pressure• Level• Volume• Interface• Density• Mass• Flow

Applications• Hot & cold temperatures• Corrosive & viscous processes• Vacuums• Foam, agitation, & other tank

disturbances• Vessels & towers

Industries• Refining• Pulp and paper• Oil & gas• Chemical• Food and beverage• Biotechnology

rosemount 3051s electronic remote sensors

Documents

eventemerson confidential27

s ers architecture

s ers digital architecture

dp level technologywire

level flanges

s electronic remote

phi plophiplo dp

systembalanced system