Lunch And Learn Presentation

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Lunch And Learn Presentation

  1. 1. Lunch and Learn 2008 1
  2. 2. R.Stahl Inc. pert s fo r Th e ex ative bal i nnov glo rote ction plosi on p ex Lunch and Learn 2008 2
  3. 3. Agenda  Introduction to R.STAHL Inc  Explosion Protection methods for hazardous Locations  Barriers and Isolators  Remote I/O and Field Device Couplers  HMI  System Solutions Lunch and Learn 2008 3
  4. 4. R.STAHL Inc.  Explosion Protected Products for Hazardous Locations  Solutions for Systems and Services to support the Chemical, Pharmaceutical, Petrochemical, Oil & Gas and Related Industries  Safety Technology applied in the Field of Electrical, Lighting and Automation solutions Lunch and Learn 2008 4
  5. 5. R.STAHL Inc. Electrical Products: Standard and Custom Control Stations, Junction Boxes, Plugs and Sockets, Pilot Lights, Pushbuttons Lighting Products: Fluorescent Lighting, Flood Lights, Emergency Lighting Lunch and Learn 2008 5
  6. 6. R.STAHL Inc. Automation Products: Zener Barriers, Galvanic Isolators, Remote I/O Systems, Fieldbus Interface Products, HMIs (Human Machine Interface) Lunch and Learn 2008 6
  7. 7. R.STAHL Inc. System Capabilities One company – Electrical, Lighting and Automation Lunch and Learn 2008 7
  8. 8. R.STAHL Inc. Where to find information..… End of 2008 www.rstahl.com www.stahl-hmi.de www.stahl-automation.com Lunch and Learn 2008 8
  9. 9. Basics of Intrinsic Safety Lunch and Learn 2008 9
  10. 10. Basics of Intrinsic Safety Explosion Confinement: Explosion proof (Flameproof) Isolation of the ignition source (Segregation): Purged / Pressurised Encapsulation Energy Release Limitation (Prevention): Intrinsic Safety NonIncendive Lunch and Learn 2008 10
  11. 11. Basics of Intrinsic Safety A simple process control loop consists of three elements –  the measurement (input) field device  the controller (PLC / DCS / SCADA) and  the final control element (output) field device Plus a fourth element  For hazardous locations with intrinsic safety protection – barrier / isolator Input Field Device Control Device Output Field Device Lunch and Learn 2008 11
  12. 12. Basics of Intrinsic Safety INTRINSIC SAFETY Intrinsic Safety is one of several design techniques that is used to protect electrical equipment and wiring in a hazardous (classified) location. Fuel, oxygen, and a source of ignition in the necessary IGN proportions must be present for combustion to occur. ITI EL O FU NS OU Intrinsic Safety is the technique that RC reduces / removes the ignition source E OXYGEN Ignition Triangle Lunch and Learn 2008 12
  13. 13. Basics of Intrinsic Safety Intrinsic safety is a design technique applied to protect electrical equipment and wiring in hazardous locations. A System Concept Not just components, how does each part fit together to create a safe system cables consumer source The technique is based on limiting energy, electrical and thermal, to levels below that which is required to ignite a specific hazardous atmospheric mix. Simplest and most effective protection method for instrumentation Lunch and Learn 2008 13
  14. 14. Basics of Intrinsic Safety Advantages of Intrinsic Safety No special constructions (e.g. flameproof enclosure) for field devices. No conduit seals Cables are also included in the explosion protection, Suitable for Division 1 applications (also Class 1 Zone 0). Calibration, function test, exchange of devices etc. possible while energized, no interruption of operation. I.S. is the only protection technique which allows “live maintenance”. Lunch and Learn 2008 14
  15. 15. Basics of Intrinsic Safety Disadvantages of Intrinsic Safety Intrinsic safety places a high demand on the designers and installers due to the system concept. Not only are there design regulations for the individual devices but also:  the correct interconnection between all devices in the I.S. circuit  the correct installation with an emphasis on protection of the I.S. circuit from external energy and grounding requirements.  only for circuits with a relatively low power consumption (perfect for process automation) Lunch and Learn 2008 15
  16. 16. Basics of Intrinsic Safety Origin of Intrinsic Safety Origin: Explosion in a mine in Wales in 1913 which killed over 400 men Cause: The energy stored in the circuit in a hazardous location. Solution: Reduce the energy stored to eliminate sparks. Signaling System The concept of intrinsic safety was born Lunch and Learn 2008 16
  17. 17. Basics of Intrinsic Safety Nonhazardous Location Hazardous Location Original method PLCs, Power Supplies Approved Approved Current method Approved Approved No Approval Required Lunch and Learn 2008 17
  18. 18. Basics of Intrinsic Safety 2. Current limitation Fuse for overload protection with resistor of Z-diode The maximum output current R is always smaller or equal UZ/R Fuse Output 1. Voltage Input (haz. area) limitation UZ Uin with Z-diode (Safe area) The maximum output voltage is always smaller or equal UZ Limit Voltage and Current under normal and foreseeable fault conditions Lunch and Learn 2008 18
  19. 19. Basics of Intrinsic Safety Zener Barrier Grounding Properly maintained, independent, low impedance. From barrier Busbar to star point of incoming power supply. <1Ω, minimum 12AWG (4mm2) 0V Use shakeproof terminals, clearly identify and make accessible for routine inspections and maintenance It is also recommended to connect the 0V of the equipment in the nonhazardous location to the barrier busbar. Lunch and Learn 2008 19
  20. 20. Basics of Intrinsic Safety Barrier and Isolator Shield Grounding Shield should only be grounded at one point and it is recommended to do this at the busbar. The field device in the hazardous location and the equipment in the nonhazardous location should not have the shields grounded. Lunch and Learn 2008 20
  21. 21. Basics of Intrinsic Safety Hazardous Location Nonhazardous Location Control Intrinsically Safe Interconnecting Apparatus Field Device Cables Associated Apparatus Control Simple Apparatus Interconnecting Apparatus Field Device Cables Associated Apparatus Lunch and Learn 2008 21
  22. 22. Basics of Intrinsic Safety Intrinsically Safe Field Device:  Device in which all circuits are intrinsically safe.  Can be mounted in a hazardous location without further protection Transmitter, Control Valve, Solenoid Any device used in a hazardous location must be approved to do so. If using intrinsic safety as the installation protection method then the device must be approved intrinsically safe. OR Simple Apparatus:  Device which does not store or generate more than – 1.5V, 100mA, 25mW Dry Contact, LED, T/C, RTD The simple apparatus rule can only be used in Intrinsic Safety and Non-Incendive field wiring installations. Lunch and Learn 2008 22
  23. 23. Basics of Intrinsic Safety Associated Apparatus:  Device which contains both IS and non IS circuits but which is constructed in such a way that the non IS circuits cannot adversely affect the IS circuits. (Protects system on hazardous side from safe area faults)  Can be mounted in a safe area or division 2 / zone 2 (if approved)  Mounted in division 1 with additional protection Zener Barrier, Galvanic Isolator Interconnecting cables:  Standard Instrumentation Cables  Capacitance and Inductance figures checked according to maximum figures allowed on the certificate for the associated apparatus. Lunch and Learn 2008 23
  24. 24. Basics of Intrinsic Safety To Recap the System Concept  An associated apparatus has to have an approved IS field device (or simple apparatus) connected to it.  An IS field device (or simple apparatus) has to be connected to an approved associated apparatus. Protects IS system Protects the Protects the from safe atmosphere atmosphere area faults from itself in the event of being cut Control Intrinsically Safe Interconnecting Apparatus Field Device or Cables Associated simple apparatus Apparatus Lunch and Learn 2008 24
  25. 25. Basics of Intrinsic Safety Associated Apparatus Zener Barrier Galvanic Isolator Lunch and Learn 2008 25
  26. 26. Basics of Intrinsic Safety Zener Barriers  Passive Device  Input and output circuits are not isolated from each other.  Ohms law, V=IR Fault current  IS ground connection Dedicated conductor run to the reference ground point - minimum 12AWG (4mm2) - <1ohm  A few barriers – many applications Lunch and Learn 2008 26
  27. 27. Basics of Intrinsic Safety Galvanic Isolators  Active device, may change the signal (RTD – 4/20mA)  Input, output and power circuits are “galvanically” isolated from each other. Fault current  Specific applications – simple choice magnetic field Energy Limitation transformer input light output light light transmitter receiver optocoupler Lunch and Learn 2008 27
  28. 28. Basics of Intrinsic Safety Advantages of Zener Barriers Galvanic Isolators  Economical solution  Galvanic isolation  Small dimensions  No I.S. ground required  Simple design  Simple engineering  Simple installation  Simple selection  Many solutions  Diagnostic LED indications  High availability  Reliable, high MTBF times  Reliable, high MTBF times  High EMI / RFI protection  No auxiliary supply  No impact of internal resistance Lunch and Learn 2008 28
  29. 29. Basics of Intrinsic Safety Zener Barriers vs Galvanic Isolators Simple Complex ~ lower MTBF Frontend engineering demand higher Application specific Versatile High dissipation (2VA) Low dissipation Loop-powered Separate power supply Higher voltage (power) available in hazardous Restricted voltage available in hazardous area and safe area Higher packing density Lower packing density Safety earth fundamental Safety earth has reduced significance Lower cost Higher cost Good frequency response <100KHz> Limited frequency response Higher accuracy and linearity <0.1%> Lower accuracy and linearity <0.25%> Imposes a '0' volt level on system Complete isolation between signals More vulnerable to lightning and other surges Less vulnerable to lightning and other surges Lunch and Learn 2008 29
  30. 30. Basics of Nonincendive Lunch and Learn 2008 30
  31. 31. Basics of Nonincendive Hazardous Location Nonhazardous Location Listed Cable Conduit or Approved Nonincendive Cable Seal Equipment Any Cable Approved Nonincendive Field Wiring Apparatus Approved Associated Nonincendive Field Wiring Apparatus Lunch and Learn 2008 31
  32. 32. Basics of Nonincendive Evaluated under Normal Conditions. includes extremes of: supply rating, ambient temperature rating and operator adjustments in field wiring also includes opening, shorting and / or grounding Simple apparatus can be used in field wiring circuits No live maintenance In class 1 zone 2, three types of protection (can be combined): nA: Non sparking nC: Normally sparking (enclosed break) nR: Restricted breathing nL: European zones only, will eventually be included in the US code. Lunch and Learn 2008 32
  33. 33. Basics of Nonincendive Nonincendive Field Wiring: Similar to Intrinsic Safety Installation per the Control Drawing Evaluate Entity Parameters of the uncontrolled parameter Evaluate Cable Inductances and Capacitances Nonincendive Field Cable Associated Nonincendive Wiring Apparatus Field Wiring Apparatus Vmax ≥ Voc Imax ≥ Isc Pmax ≥ Po Ci + CCable ≤ Ca Li + LCable ≤ La Lunch and Learn 2008 33
  34. 34. Automation Product Portfolio Interface Fieldbus Solutions Solutions 9400 Series 9100 Series ET & MT Series HMI Solutions 9400 Series + System Solutions 9000 Series Lunch and Learn 2008 34
  35. 35. Automation Product Portfolio Technology Overview PLC / DCS PLC / DCS PLC / DCS I/O Cards Bus Card Bus Card I.S. Fieldbus Power Supply & I.S. Isolating Conditioner - FF H1 Interface Repeater Segment coupler - PA Profibus DP FF H1 Modbus RTU Field Device Remote I/O Profibus PA Fieldstations Couplers Terminal Box Conventional and HART Field Devices FF H1 and Profibus PA Field Devices Lunch and Learn 2008 35
  36. 36. Automation Product Portfolio Interface Solutions Associated Apparatus: Zener Barriers – 9000 Series Lunch and Learn 2008 36
  37. 37. Automation Product Portfolio Features 2 channels in ½”, 12mm Replaceable back-up fuse Ground connection via Din Rail Labeling plate Alternative ground connection Lunch and Learn 2008 37
  38. 38. Automation Product Portfolio Features & Benefits  Installation allowed (certified) in Division 2 / Zone 2 Flexible installation possibilities  One replaceable fuse for all safety barrier versions Economic spare part handling  Change of replaceable fuse allowed during operation and in Division 2 / Zone 2 Simple maintenance and repair  Certified to FM, CSA and ATEX International acceptance Extended temperature range –20...+60 °C Robust  Largest product range on the market (170 versions) A solution for (nearly) all applications Standard and oddball Lunch and Learn 2008 38
  39. 39. Automation Product Portfolio Interface Solutions Associated Apparatus: Galvanic Isolators – 9100 Series Lunch and Learn 2008 39
  40. 40. Automation Product Portfolio Features All standard applications in LEDs for power supply and 2 channel versions (0.7”, channel errors 17.6mm) 3 types of removable terminals DIP switches for various – screw, spring clamp, functions insulation displacement Case Design: Clear / yellow plastic cover and Ventilation slits (up to 70oC) large label area Vibration resistant up to 4g Lunch and Learn 2008 40
  41. 41. Automation Product Portfolio Feature – 3 solutions Individual mounting on standard 35mm DIN-rail Control systems Group-mounting with solution with power bus and pre-manufactured central power supply termination panel Lunch and Learn 2008 41
  42. 42. Automation Product Portfolio Features Pac Bus Pac Carrier Lunch and Learn 2008 42
  43. 43. Automation Product Portfolio Fieldbus Solutions 9400 Series 9100 Series ET & MT Series HMI Solutions 9400 Series + System Solutions 9000 Series Lunch and Learn 2008 43
  44. 44. IS 1 and IS Bus Overview Hazardous Location Remote I/O System Since 1986 2nd Generation from R.Stahl Install in any hazardous location worldwide without additional explosion protection Profibus DP, Modbus RTU Modbus TCP over Ethernet (Fiber optic) – Q2 2009 Lunch and Learn 2008 44
  45. 45. IS 1 and IS Bus Overview ABB Automation Systems, AEG Allen Bradley Industries and Environment Pharmaceutical Alstom Chemical Eurotherm Ammunition Facilities Emerson Process Management Distilleries / Breweries Foxboro Waste Water Treatment GE Fanuc Petrochemical Honeywell Power Generation Intelution Oil and Gas Mitsubishi FPSO Modicon Hot - Desert Locations Offshore Drilling and Production Motorola Cold - Arctic Circle Aerospace Omron Wet - Offshore Platforms Pulp and Paper Saia Vibration and Shock Automotive Schneider Automation - Ship and Turbine Installations Mining Siemens Corrosive Marine Xytec - Chemical and Petrochemical Industries Tank Farms Yokogawa Lunch and Learn 2008 45
  46. 46. IS 1 and IS Bus Overview All you need is … 3 components: BusRail and Accessories CPU and Power Module Input / Output Modules Lunch and Learn 2008 46
  47. 47. IS 1 and IS Bus Overview Communication and Power Supply Unit in one Module (CPM): Provides power for I/O modules and signals No power calculations - 1 off CPM Div 2 + 16 I/O Modules - 1 off CPM Div 1 + 8 I/O Modules Profibus DP and ModBus RTU LCD Display Division 2 / Zone 2 CPM ServiceBus Division 1 / Zone 1 CPM Lunch and Learn 2008 47
  48. 48. IS 1 and IS Bus Overview Various I/O Modules – Any Division or Zone Analog Input and Output, standard and HART Digital Input and Output, frequency RTD and THC Inputs Multi channel modules, attractive pricing No keying or Dip switch settings Open and short circuit monitoring Plug-in, Removable I/O Terminals Ease of wiring Removal of modules without disturbing the signal wiring Lunch and Learn 2008 48
  49. 49. IS 1 and IS Bus Overview BusRail for Power and Data: Snaps easily into standard 35/15 DIN-Rail Builds up from 2 Module and 4 Module lengths No wiring required Few connection contacts Less failure points High reliability Lunch and Learn 2008 49
  50. 50. IS 1 and IS Bus Overview  Ethernet communication link - Q2 2009 New CPU, new power supply module separate Division 1 / Zone 1 Fiber optic physical link Protocols: 1. Modbus TCP 2. FF HSE 3. Profinet or Ethernet IP Lunch and Learn 2008 50
  51. 51. IS 1 and IS Bus Overview Hazardous Location Fieldbus Products Lunch and Learn 2008 51
  52. 52. IS 1 and IS Bus Overview Field device Couplers Ex e / Ex i and Ex e / Ex e NI / Ex i and NI / NI Trunk Field devices Ex e FISCO, FNICO, Ex e NI Lunch and Learn 2008 52
  53. 53. IS 1 and IS Bus Overview Enclosure Options Lunch and Learn 2008 53
  54. 54. IS 1 and IS Bus Overview System Ethernet Future Cntrl I/O I/O I/O Bus Bus NIC System Solutions Modbus TCP Black Box 2009 ???? System Solutions now Industrial Profinet Ethernet Profibus DP Ethernet IP FF H1 FF HSE ... Division & Zone 1 & 2 Division & Zone 1 & 2 V RIO: Remote I/O Power Supply FPS: Fieldbus Power Supply RIO Remote I/O FPS FB: Fieldbus Barrier I/O I/O Bus FB FB FB Classic H H H HART FF H1 Lunch and Learn 2008 54
  55. 55. Automation Product Portfolio 9400 Series 9100 Series ET & MT Series HMI Solutions 9400 Series + System Solutions 9000 Series Lunch and Learn 2008 55
  56. 56. HMI Overview MT Series Non-Hazardous locations Zone 2, Zone 22 ET Series Zone 1, 2, 21, 22 Class 1 Zone 1 Class 1 Division 1 Class 1 Division 2 Lunch and Learn 2008 56
  57. 57. HMI Overview Open HMI – Operator Interfaces - Systems with standard hardware Integrated hardware and software interfaces and open operating Engineering with SPSPlus WIN systems (e.g. Windows XP Embedded ) Open HMI / Falcon Series Eagle Series Panel PC / Thin Client MT Class 1 Div 2 Zone 2, 22 Full Color Touchscreen ET Class 1 Div 1 & Div 2 Zone 1, 2, 21, 22 Monochrome DNV, GL Div 1 with simple purging Lunch and Learn 2008 57
  58. 58. HMI Overview HMI Automation Systems Applications HMI System Interfaces HMI Industry Applications Pharmaceutical DCS / PLC Manufacturer Chemical ABB Ammunition Facilities <Falcon Allen Bradley Distilleries / Breweries General Waste Water Treatment Emerson Petrochemical Fisher-Rosemount Power Generation Foxboro Oil and Gas >Eagle GE Fanuc FPSO (Floating Production Storage Offloading Vessel) Honeywell Offshore Drilling and Production Mitsubishi Aerospace Omron Pulp and Paper Schneider Automation Automotive Siemens Mining Yokogawa Marine Tank Farms <Open HMI Lunch and Learn 2008 58
  59. 59. HMI Overview Temperature range: Repair and support -20°C - +70°C (Falcon Series) in Houston, Texas -20°C - +55°C (Eagle/Open HMI) Factory Trained Technicians Open HMI / Falcon Series Panel PC / Eagle Series Thin Client MT Class 1 Div 2 Zone 2, 22 ET Class 1 Div 1 & Div 2 Zone 1, 2, 21, 22 DNV, GL Div 1 with simple purging Lunch and Learn 2008 59
  60. 60. HMI Overview  Factory Trained Technicians  Repaired here in Houston, Texas  Quick turn-around on your repairs.  Encapsulated modular design.  System design and start up assistance available.  Local HMI support. Lunch and Learn 2008 60
  61. 61. Automation Product Portfolio 9400 Series 9100 Series ET & MT Series 9400 Series + System Solutions 9000 Series Lunch and Learn 2008 61
  62. 62. R.Stahl Inc Systems Solutions providing panels UL508 and UL698 ATEX Listed panels Control and Power solutions for all applications Class 1 Division 1 Remote I/O Solution Lunch and Learn 2008 62
  63. 63. R.STAHL Inc. System Capabilities >Both Zone 1 and Class 1 Division 2 HMI Applications Lunch and Learn 2008 63
  64. 64. R.STAHL Inc. System Capabilities Combined enclosure applications for various installations Plus Purged Solutions Lunch and Learn 2008 64
  65. 65. Automation Department THANK YOU FOR LISTENING ANY QUESTIONS? >Presenter: >Contact info: Automation@rstahl.com Tel: 800-782-4357 Fax: 832-476-1840 Lunch and Learn 2008 65

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