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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. Process Level Market by Technology *. Straightforward measurement technique Easily verified and calibrated

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Rosemount 3051S Electronic Remote Sensors

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  1. Rosemount 3051SElectronic Remote Sensors A Digital Upgrade to a Proven Technology

  2. DP Level is a Proven and Successful Technology Process Level Market by Technology* • Straightforward measurement technique • Easily verified and calibrated • Flexibility enables use in variety of applications (mass, density, interface) Other 26% DP 30% Ultrasonic 12% Radar 17% Switches 15% Dry Leg Wet Leg Balanced System 3051S ERS Tuned-System NEW *VDC Global Process Level (2005), ARC Global Radar Study (2008), F&S Global Level Sensors (2005)

  3. 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 Two-Wire 4-20 mA Output with HART PHI

  4. 3051S ERS Provides Additional DP Level Capabilities Simplified Installations PLO Improved Performance Wire Simplified Maintenance & Spares Inventory DP = PHI – PLO 4-20 mA Access to New Information PHI Synchronized & Integrated Solution

  5. 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 3. Perform a system zero trim • Establishes true zero-based DP measurement • No zero elevation calculation required 1 3 3051S ERS Architecture Supports Flexible Installations 3051SAM with Featureboard 3051SAM Remote Display with Featureboard 3051SAM with level flanges 3051SAL with Featureboard 3051SAL

  6. 3051S ERS Digital Architecture Delivers Improved Performance Direct Connection to Tank Reduces Time Response Digital Architecture Eliminates Measurement Drift 0.5 sec. 2.5 sec. Transmitter with 10 ft (3 m) Capillary Direct-Mounted ERS Transmitter Wet Leg Dry Leg Capillary 3051S ERS System Evaporation Electrical Wire Condensation Fill Fluid Density & Volume Changes with Temperature Digital architecture eliminates temperature effects

  7. 3051S ERS Simplifies Maintenance and Spares Inventory Replace one transmitter vs. entire capillary assembly Simplify spares inventory & standardize on common ERS components X • Corrosion • Process-coated diaphragm • Hydrogen permeation

  8. 3051S ERS Provides Greater Insight Into Your Process Monitor PHIand PLOpressures in real-time Automatic & synchronized DP calculation Process alerts enable proactive maintenance practices Scaled Variable converts DP into level & volume measurements

  9. 20-Point Scaled Variable Simplifies Configuration & Commissioning Automatically convert DP into level, volume, mass, or other variables 3 Easy Configuration Options • Direct • Manually provide up to 20 “DP vs. Scaled” pairings 1 25 mbar = 17.9 LITER • Tank Formulas • Scaled Variable using basic tank dimensions 2 • Strapping Table • Scaled Variable using tank strapping table 3

  10. 3051S ERS Provides an Easy, Integrated Solution Do-it-Yourself (Two Transmitters) 3051S ERS PLO P2 P1 ∆P No error from change in static pressure (∆P) ∆P P2 DP DP PHI P1 • Not synchronized • 2x wiring costs • 2x required I/O • DCS programming • Difficult to “zero” DP • Synchronized measurements • Single 2-wire 4-20mA loop • No DCS programming • Easily zeroed & calibrated

  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

  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 flangedseals was easily retrofitted on the Alkylation reactor and eliminated unplanned process shutdowns.

  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 Application Level measurement on black liquor vessel ZellstoffPöls Austria was able to address reoccurring maintenance problems and improve their level measurement by upgrading to a 3051S ERS system.

  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 Application Vacuum 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”

  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 Application Level 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.”

  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 control • Application • 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

  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 Application 20 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

  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 Application Level 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.

  19. New 3051S Electronic Remote Sensors Have Proven Successes Proven ERS Applications Distillation Tower Chemical Holding Tank Enzyme Fermentation Batch Tank Vacuum Tank Chemical Reactor Black Liquor Level Beer Storage Glycerin Refining Starch Level • ERS Applications Characteristics • Tall Spans • Temperature Variation • Heat Tracing • Plugged Impulse Lines • Low Static Pressure • Excessive Impulse Piping / Capillary • Measurement Drift 3051S ERS System

  20. 3051S ERS Compliments Traditional DP Level Technology Electronic Remote Sensors • Sensors sized on amount of static pressure + DP column • GP Sensor Span = 103.6 psi • (2868 in.H20) 100 PSI 100 psi Tuned-System™ Assembly • Sensor sized on DP column only • DP Sensor Span = 100 in.H20 100 in.H20 100 in.H20 High Pressure Application Example • ERSTuned-System • ±2.8 in.H20 ±1.4 in.H20 • 25 F Ambient Temperature Change VS

  21. Traditional DP Level Technologies Still Have Key Applications and Benefits • Traditional DP Level Technologies • Tuned-System Assembly • Balanced Capillary System • DP transmitter with wet leg • DP transmitter with dry leg • Application Characteristics • Short Spans • High Pressures • Indoor Vessels • Stable Temperatures • Simple Installations • Wireless Tuned-System Assembly

  22. Achieve Success with Rosemount DP Level in More Places than Ever Before Balanced System 3051S ERS Tuned-System Wet Leg Dry Leg • Measurements • Pressure • Level • Volume • Interface • Density • Mass • Flow • Industries • Refining • Pulp and paper • Oil & gas • Chemical • Food and beverage • Biotechnology • Applications • Hot & cold temperatures • Corrosive & viscous processes • Vacuums • Foam, agitation, & other tank disturbances • Vessels & towers

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