Transcript Install Guide: Rosemount 3051S Electronic Remote Sensors

Rosemount 3051S
Electronic Remote Sensors
A Digital Upgrade to a Proven Technology
DP Level is a Proven and Successful
Technology
Level 



Pressure
Specific Gravity
Straightforward measurement technique
Easily verified and calibrated
Flexibility enables use in variety of
applications (mass, density, interface)
3051S ERS
Tuned-System
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Global
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Balanced System
Process Level Market
by Technology*
Other
26%
Ultrasonic
12%
Switches
15%
Wet Leg
DP 30%
Radar
17%
Dry Leg
Process Level (2005), ARC Global Radar Study (2008), F&S Global Level Sensors (2005)
New 3051S Electronic Remote Sensors
Enhance DP Level Technology
PLO
DP Calculated Electronically
• Two Pressure Sensors
• Electronics Featureboard
Wire
Utilizes Proven 3051S
Sensor Platform
DP = PHI – PLO
4-20 mA
PHI
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Two-Wire 4-20 mA Output
with HART
3051S ERS Provides Additional DP Level
Capabilities
Simplified
Installations
PLO
Improved
Performance
Wire
DP = PHI – PLO
4-20 mA
PHI
Simplified
Maintenance &
Spares Inventory
Access to New
Information
Synchronized &
Integrated Solution
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3051S ERS Simplifies Installation Practices
1. Independently install each sensor
– Direct-mount without pipe stand, brackets,
and other hardware
– Can be installed by a single instrument tech
1
2. Wire sensors together
– Non-proprietary electrical wire
– Easy to install around catwalks, on
distillation columns, etc.
– Eliminate insulation and heat tracing
2
1
3. Perform a system zero trim
3
– Establishes true zero-based DP measurement
– No zero elevation calculation required
3051S ERS Architecture Supports Flexible Installations
3051SAM
3051SAL with
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Featureboard
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3051SAM with
Featureboard
3051SAL
Remote Display
with Featureboard
3051SAM with
level flanges
3051S ERS Digital Architecture Delivers
Improved Performance
Direct Connection to Tank Reduces Time Response
Transmitter with
10 ft (3 m) Capillary
Direct-Mounted
ERS Transmitter
Digital Architecture Eliminates Measurement Drift
Wet Leg
Dry Leg
Capillary
Evaporation
3051S ERS
System
Electrical Wire
Condensation
Fill Fluid Density &
Volume Changes with
Temperature
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Digital architecture
eliminates temperature
effects
3051S ERS Simplifies Maintenance and
Spares Inventory
Replace one transmitter vs.
entire capillary assembly
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Simplify spares inventory &
standardize on common ERS
components
• Corrosion
• Process-coated diaphragm
• Hydrogen permeation
3051S ERS Provides Greater Insight Into
Your Process
Automatic &
synchronized DP
calculation
Process alerts enable
proactive maintenance
practices
Scaled Variable
converts DP into
level & volume
measurements
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Monitor PHI and PLO
pressures in real-time
20-Point Scaled Variable Simplifies
Configuration & Commissioning
Automatically convert DP into level, volume,
mass, or other variables
3 Easy Configuration
Options
1
Direct
• Manually provide up to 20
“DP vs. Scaled” pairings
25 mbar
2
Tank Formulas
• Scaled Variable using basic
tank dimensions
3
Strapping Table
• Scaled Variable using tank
strapping table
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= 17.9
LITER
3051S ERS Provides an Easy, Integrated
Solution
Do-it-Yourself (Two Transmitters)
3051S ERS
PLO
P2
∆P
P1
DP
DP
PHI
P1
• Not synchronized
• 2x wiring costs
• 2x required I/O
• DCS programming
•[FileDifficult
to “zero” DP
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∆P
No error from
change in static
pressure (∆P)
P2
•
•
•
•
Synchronized measurements
Single 2-wire 4-20mA loop
No DCS programming
Easily zeroed & calibrated
Chevron Phillips Chemical (Borger, TX)
Achieved Success with 3051S ERS

CHALLENGE
– Bridle with magnetic float and unreliable
heat tracing
– False level measurement & unplanned
shutdowns

Application
• 30 ft (9 m) process
storage tank
• Ambient Temp
0 to 100 F
(-17 to 38 C)
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)
“We have had no lost production and better on-stream operation since installing ERS”
- Tim
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Anderson, I&E Reliability Team Leader, Chevron Phillips Chemical, Borger, TX
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

Application
• Alkylation reactor
• Level measurement
of effluent liquid
RESULTS
– 100% measurement reliability since
installation (3+ years)
– No work orders or requests for
troubleshooting
The 3051S ERS assembly with flanged seals was easily retrofitted on the
Alkylation reactor and eliminated unplanned process shutdowns.
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Austrian Pulp and Paper Mill Decreases
Maintenance Costs with ERS Technology
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CHALLENGE
– Excessive maintenance costs on wet leg
installation
• Plugged lines
• Heat tracing
• Vacuum spikes
– Suboptimal black liquor output
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SOLUTION
– 3051S ERS system

Application
Level measurement
on black liquor vessel
RESULTS
– Elimination of heat tracing and water
purging
– Increased reliability and repeatability of level
measurement
Zellstoff Pöls Austria was able to address reoccurring maintenance problems and improve
[File Name or Event] their level measurement by upgrading to a 3051S ERS system.
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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

Application
Vacuum tank on lime
mud filter
RESULTS
– Elimination of wet leg
– Only one shutdown over 2-year period
– Process runs in automatic close to 100% of
time
“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
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the time”
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Biotech Facility Increases Throughput on
Fermentation Vessel with 3051S ERS
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CHALLENGE
– Inconsistent batches
– 3-5% measurement error
– Unable to calculate yield

SOLUTION
– 3051S ERS system with hygienic TankSpud seals
Application
Level measurement
on enzyme
fermentation vessel
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
RESULTS
– Measurement error improved to less than <
0.5%
– Drastic time response improvement
– Achieved consistent, high-quality batches
“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.”
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
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SOLUTION
– 3051S ERS with EFW extended diaphragm
seal

Application
• Brine level
measurement
• 33 ft (10 m)
evaporator
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RESULTS
– Extended seal used at bottom of tank
eliminated plugging
– Digital architecture enabled optimized
control
“The ERS system has been
installed for months, much to our
total satisfaction”
- Jean-Marc Deconto, Solvay engineer
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
Application
20 ft (8.3 m) Glycerin
refining tower

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
“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.”
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- Project engineer
Silicon Manufacturer Reduces Inventory
Costs with 3051S ERS

CHALLENGE
– Excessive capillary caused measurement
error > 5%
– Inconsistent batches
• Material shortages
• High scrap rates

Application
Level control in silicon
holding tank
SOLUTION
– 3051S ERS system

RESULTS
– Accurate level measurement
– Achieved consistent batches
– No unplanned shutdowns
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The long lengths of capillary with the previous installation were
completely eliminated with the digital architecture of the 3051S
ERS system.
New 3051S Electronic Remote
Sensors Have Proven Successes
Proven ERS
Applications
ERS Applications
Characteristics
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
•
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•
•
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Distillation Tower
Chemical Holding Tank
Enzyme Fermentation
Batch Tank
Vacuum Tank
Chemical Reactor
Black Liquor Level
Beer Storage
Glycerin Refining
Starch Level
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3051S
ERS
System
•
Tall Spans
Temperature Variation
Heat Tracing
Plugged Impulse Lines
Low Static Pressure
Excessive Impulse
Piping / Capillary
Measurement Drift
3051S ERS Compliments Traditional DP
Level Technology
Electronic Remote Sensors
100
PSI
• Sensors sized on amount of static
pressure + DP column
• GP Sensor Span = 103.6 psi
(2868 in.H20)
100
psi
Tuned-System™ Assembly
100
in.H20
• Sensor sized on DP column only
• DP Sensor Span = 100 in.H20
High Pressure Application Example
ERS
±2.8 in.H20
VS
Tuned-System
±1.4 in.H20
25 F Ambient Temperature Change
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100
in.H20
Traditional DP Level Technologies Still
Have Key Applications and Benefits
Traditional DP Level
Technologies
Application
Characteristics
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•
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•
Tuned-System
Assembly
Balanced Capillary
System
DP transmitter with wet
leg
DP transmitter with dry
leg
TunedSystem
Assembly
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Short Spans
High Pressures
Indoor Vessels
Stable Temperatures
Simple Installations
Wireless
Achieve Success with Rosemount DP Level
in More Places than Ever Before
Measurements
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Applications
Industries