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 [File Name or Event] 2 EmersonSlide Confidential *VDC Global 27-Jun-01, Slide 2 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 [File Name or Event] 3 EmersonSlide Confidential 27-Jun-01, Slide 3 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 [File Name or Event] 4 EmersonSlide Confidential 27-Jun-01, Slide 4 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 [File Name or Event] Featureboard 5 EmersonSlide Confidential 27-Jun-01, Slide 5 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 [File Name or Event] 6 EmersonSlide Confidential 27-Jun-01, Slide 6 Digital architecture eliminates temperature effects 3051S ERS Simplifies Maintenance and Spares Inventory Replace one transmitter vs. entire capillary assembly [File Name or Event] 7 EmersonSlide Confidential 27-Jun-01, Slide 7 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 [File Name or Event] 8 EmersonSlide Confidential 27-Jun-01, Slide 8 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 [File Name or Event] 9 EmersonSlide Confidential 27-Jun-01, Slide 9 = 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 Name or Event] Slide 10 Emerson Confidential 27-Jun-01, Slide 10 ∆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 [File Name or Event] Slide 11 Emerson Confidential 27-Jun-01, Slide 11 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. [File Name or Event] Slide 12 Emerson Confidential 27-Jun-01, Slide 12 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 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. Slide 13 Emerson Confidential 27-Jun-01, Slide 13 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 [File Name or Event] the time” Slide 14 Emerson Confidential 27-Jun-01, Slide 14 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 TankSpud seals Application Level measurement on enzyme fermentation vessel [File Name or Event] Slide 15 Emerson Confidential 27-Jun-01, Slide 15 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 SOLUTION – 3051S ERS with EFW extended diaphragm seal Application • Brine level measurement • 33 ft (10 m) evaporator [File Name or Event] Slide 16 Emerson Confidential 27-Jun-01, Slide 16 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.” [File Name or Event] Slide 17 Emerson Confidential 27-Jun-01, Slide 17 - 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 [File Name or Event] Slide 18 Emerson Confidential 27-Jun-01, Slide 18 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. • • • • • • Distillation Tower Chemical Holding Tank Enzyme Fermentation Batch Tank Vacuum Tank Chemical Reactor Black Liquor Level Beer Storage Glycerin Refining Starch Level [File Name or Event] Slide 19 Emerson Confidential 27-Jun-01, Slide 19 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 [File Name or Event] Slide 20 Emerson Confidential 27-Jun-01, Slide 20 100 in.H20 Traditional DP Level Technologies Still Have Key Applications and Benefits Traditional DP Level Technologies Application Characteristics • • • • • • • • • • Tuned-System Assembly Balanced Capillary System DP transmitter with wet leg DP transmitter with dry leg TunedSystem Assembly [File Name or Event] Slide 21 Emerson Confidential 27-Jun-01, Slide 21 Short Spans High Pressures Indoor Vessels Stable Temperatures Simple Installations Wireless Achieve Success with Rosemount DP Level in More Places than Ever Before Measurements [File Name or Event] Slide 22 Emerson Confidential 27-Jun-01, Slide 22 Applications Industries