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Transcat + Emerson Webinar: Maximize Safety and Reliability with the Only Wired HART Level Detector
- 1. Maximize Safety andReliability with the Only Wired HART Level Detector New Generation Vibrating Fork Switches
- 2. Presenter Introduction Kevin Thomas LevelInstrumentation Expert, Emerson • Kevin Thomas, is a process level instrumentation expert with Emerson. He collaborates with engineers to solve challenging level measurement and monitoring situations across industries including Refining, Chemical, Life Sciences, Food & Beverage, Pulp & Paper, Power, Metals & Mining, and Oil & Gas. • Kevin lives in Minneapolis, MN and enjoys spending time outdoors with family and friends, and is a motorsports enthusiast including boating, snowmobiling and motorcycling.
- 3. Agenda Importance of PointLevel Detection The Next Generation of Point Level Detection Applications Specifications How to Order
- 4. Why You NeedPoint Level Detection of Liquids and Sediments •Prevent spills •Keep your workers safe •Improve efficiency •Prevent damage to equipment
- 5. Legacy Point LevelDetection Challenges • Unreliability with overfill prevention solutions – Potential negative impact on your workers, process, plant, the environment AND bottom line • Trusting measurement accuracy, especially in challenging applications such as in low density fluids or when level changes rapidly • Lack of insight into device health – Fear of failing hardware causing process shutdowns • Risk of missing a measurement in low-density fluids • Risk of nuisance alarms from splashing or turbulence • Unreliability with sand and sediment detection • Visual checks are time consuming and carry high risk especially in hazardous areas • Risk of plugged flow lines, damage & shutdown • Alternative monitoring technology is complex / costly
- 6. Point level measurementand control is born Ballcock is invented Mobrey launches first Hi / Lo boiler control KDG / Mobrey™ Magnetic Float Switch invented Capacitance / Resistance Probes Ultrasonic gap switches 1910 - 1920 1950 …Level was everywhere! 1960 1970 1980 2010 In the beginning… World’s first wireless HART fork level detector Rosemount 2160 The Evolution of Point Level Detection “Intelligent” Vibrating Fork Switches Rosemount 2130 Advanced Diagnostics, Fault Relay Vibrating Fork Switches Basic I/O output
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- 8. Rosemount 2140 LevelDetector Rosemount 2140:SIS Level Detector
- 9. The World’s FirstWired HART® Vibrating Fork Level Detector • HART registered • Compatible with HART 5 and HART 7 Hosts • Integrate into existing wired HART automation loops without extra wiring “The HART Protocol is the global communication standard for intelligent process measurement and control with more than 40 million HART- communicating devices installed in the process automation industry worldwide.” FieldComm Group
- 10. A New GenerationOf… Reliability for Peace of Mind Reliability Ease-of-use Unique Functionality Simplifies Your Process Dedicated to Safety Safety
- 11. A New GenerationOf… Reliability for Peace of Mind Reliability Ease-of-use Unique Functionality Simplifies Your Process Dedicated to Safety Safety
- 12. 12 Tried, Tested andTrusted Technology Utilized Thoughout Development of Rosemount 2140 • Fast-drip short fork fork design ensures reliable, repeatable switching across many process types – Rapid switching even in viscous or sticky applications with Emerson’s time-proven design – Consistent switch-point independent of orientation – No calibration and limited on-site maintenance • Robust dual compartment housing – 2nd layer of protection against process leaks or ingress from the environment Point level detection you can trust, even in the most challenging applications Reliable Electronics compartment Terminal compartment Self draining conduits
- 13. • Rosemount 2140’sdiagnostics continuously monitor electronic and mechanical health and will alert if attention required – If fault detected, operator alerted, output forced to safe “OFF” condition Know Your Point Level Detector Will Work When it is Needed Reliable Fork corrosion Checks fork frequency Excessive corrosion to fork Advises if outside normal operating band Fork damage Checks fork frequency Advises if outside normal operating band Internal function check Internal wire disconnect / break Internal process memory failure Electronics temperature out of limits Internal damage to sensor LOI/ LCD failure (if fitted)
- 14. 14 Configure Alerts andDetect Emerging Conditions Before They Become a Problem with New Smart Diagnostics Suite Keep processes running: Schedule proactive maintenance during planned downtime Power Advisory • Continuously monitors loop power • User alerted if the properties change • Can help detect emerging problems such as damage to internal electronics or corrosion Process Alerts • User can configure limits on HART variables • User alerted when variable deviates outside of configured limits Frequency Profiling • Continuous monitoring of fork frequency • Detect emerging conditions such as media build up and fork corrosion Reliable
- 15. • Know processcharacteristics as well as your point level • Detect emerging conditions • Scaled Variable function allows you to map a HART Variable to the 4-20mA analog output Rosemount 2140 Detector is “More Than a Switch”… Get More Device and Process Insight With HART Reliable Analog Output • Your current output is always visible Percent of Range • % of analog 4-20mA • 4mA= 0%, 20mA= 100% • <0% or >100% = alarm Sensor Frequency • Identify emerging forks build up, avoid risk of bridging • Infer changing or differing media properties Electronics Temperature • Temperature within housing • Ensure safe operating conditions are not compromised
- 16. 16 Selectable Liquid DensityCapability – Precise Switching Across Many Process Types • The Rosemount 2140 is ready for use “out of box”, but four different media density settings fine tune sensitivity and optimize switching reliability and repeatability – Correct setting ensures switch point is close to the center of the fork – “Media Learn” function auto selects most appropriate setting for the process 1. Low- e.g. Propane 400Kg/m3 – 600Kg/m3 (SG 0.4 - 0.6) 2. Medium- e.g. Alcohol 500Kg/m3 – 900Kg/m3 (SG 0.5 – 0.9) 3. Standard- e.g. Water 800Kg/m3 – 1300Kg/m3 (SG 0.8 – 1.3) 4. High- e.g. Acid 1200Kg/m3 – 3000Kg/m3 (SG 1.2 – 3.0) Robust point level measurement and overfill prevention even in low density fluids or when level changes rapidly Reliable Switch point
- 17. A New GenerationOf… Reliability for Peace of Mind Reliability Ease-of-use Unique Functionality Simplifies Your Process Dedicated to Safety Safety
- 18. 18 Save Time andSimplify Processes with Remote Functionality • Access Smart diagnostics and test device integrity without having to climb the tank • No need to enter into hazardous areas: perform routine inspections and tests from control room • Functions easy to perform by a single operator Save time, increase process availability, worker safety and efficiency Less of this More of this… Or even this… Ease-of-use
- 19. Proof Testing MadeEasy with Remote Partial Proof-Test input processing output 1. Partial Proof-Test Test checks processing and output stages 2. All output states “exercised” – High, low and alarm current levels cycled 3. Device returns to operation after test – No risk of leaving in test mode Now you can: • Save space in the control panel: Fully integrated capability with no extra point to point wiring • Activate from the control room with HART command • Perform test without removing instrument from the vessel • Avoid process interruptions: no need to raise / lower liquid level • Multi-drop if testing multiple devices Ease-of-use
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- 21. Unique Media LearnOptimizes Performance with No Risk of Human Error • Media Learn “fine tunes” device according to the process SG • Device auto selects the most appropriate Media Density band • Ensures switch point is close to fork center regardless of SG • Perform once on commissioning – Simply immerse the fork in process fluid & activate procedure; it takes seconds • Very simple, quick procedure maximizes reliability and repeatability Ease-of-use Low SGHigh SG Consistent switch point Low SGHigh SG Now you can • Optimize performance with no need to know the process fluid SG • Have a consistent switch point in all process fluids • Eliminate missed events
- 22. Detect Sand andSediment Build-Up in your Vessel • Rosemount 2140 can detect if there is sediment building up in your tank or separator • This special setting detects state change between liquid and sediment, as opposed to air and liquid –When set to “Sand Detection”, Rosemount 2140 ignores air / liquid interface –Instead Rosemount 2140 detects liquid / sediment interface Ease-of-use Now you can: • Continuously monitor sediment level; avoid excess build-up • Proactively schedule vessel clean-outs during periods of downtime • Reduce risk of equipment damage from sediment being drawn into lines • Optimize separator capacity and process efficiency
- 23. A New Generationof… Reliability for Peace of Mind Reliability Ease-of-use Unique Functionality Simplifies Your Process Dedicated to Safety Safety
- 24. Deceptively Alike. YetDifferent. 24 Rosemount 2140:SIS Safety Instrumented Systems (SIS) Rosemount 2140 Basic Process Control Systems (BPCS) Safety
- 25. 25 • Combination ofrobust design, intelligent diagnostics and partial proof-testing functionality helps reduce Probability of Failure on Demand and exposure to risk Probability of less than 1 dangerous failure in 8,000 years Safety “First and foremost I want to be certain that the device switches reliably and safely. Having a high SFF is testament to this. Having HART to confirm and report this brings a wealth of additional information which in this plant is critical. Information about the process to this plant is critical!” Steve Hodges, Synthomer, UK Rosemount 2140:SIS is One of the Safest SIL2 Liquid Level Detectors on the Market Today
- 26. Rosemount 2140:SIS forCritical & Functional Safety Applications • IEC61508 certified to SIL2 • 3rd party assessment by Exida • Safe Failure Fraction up to 97.7% • SIL branding identifies safety function – Yellow tag and band • QT option for document pack – All data provided to calculate PFD • Incorporates “proven in use” technology with new improved design steps • Superior failure detection: diagnostics coverage >91% • Very low dangerous undetected failure rate – 13 per 109 hours (FIT) • Supports increased proof testing time intervals • Unique remote partial proof- test – Easier and safer to keep in control of proof testing and PFD Designed to maximize safety & reliability Trust your overfill prevention device is safe
- 27. 27 Rosemount 2140:SIS SupportsExtended Comprehensive Proof Testing Interval More freedom to extend the comprehensive proof test interval and fit around the plant schedule Functional SafetySafety With superior reliability, Rosemount 2140:SIS remains compliant under SIL2 for many years 0 0.002 0.004 0.006 0.008 0.01 0.012 0 1 2 3 4 5 6 7 8 9 10 ProbabilityofFailureonDemand Years PFD, no proof test PFD, PPT every year PFD, CPT every year Series10 SIL2 PFD, no proof test PFD, annual partial proof test PFD, annual comprehensive prooftest
- 28. HART Protection AgainstUnauthorized or Unintended Access and Changes Rosemount 2140 and Rosemount 2140:SIS have several means of protection: • Local Hardware Switch – “Padlock closed” position prevents device configuration changes via LOI or HART communication – Prevents accidental activation Proof-Test via push buttons or communications • User-selectable password – 4-digit PIN may be defined via HART communications or LOI – Protects against unauthorized changes to device configuration • “Lock Device” command – Allows Host System to prevent changes to the device configuration via another HART master or via the LOI • “In Write Protect Mode” – Whilst LOI menu is navigated, device responds accordingly to any HART Write-Command Nameplate prevents accidental activation of test and config buttons Safety
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- 30. Rosemount 2140 and2140:SIS Suitable for Many Different Industries and Applications Sand & sediment detection Rosemount 2140 detects sediment build up to maximize vessel/ separator efficiency Reduce risk of equipment damage and process shutdown High and low level alarms Manage maximum and minimum tank levels and receive alerts to emerging issues such as coating or corrosion with Smart Diagnostics Monitoring and control Rosemount 2140 optimizes switching time and accuracy in small vessels or pipes, preventing potentially dangerous run-dry situations. Overfill prevention and Automatic Overfill Prevention Systems Rosemount 2140:SIS for protection even in turbulent or harsh process conditions. Unique remote partial proof- testing functionality.
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- 32. Rosemount 2140 Rosemount2140:SIS Certifications Explosion proof Intrinsically safe Safe area / ordinary location Overfill protection (DIBt/TÜV WHG) Coming soon Coming soon Safety system certified to IEC 61508 (SIL2) Output Loop powered 4-20mA HART (configurable) Functional testing Local device test Local partial proof test Remote partial proof test Diagnostics Smart Diagnostics Suite Media Learn Sand Switch Scalable variable output Housing Low copper aluminium Stainless steel Wetted material 316L Stainless steel ECTFE copolymer, coated 316L SST Corrosion-resistant nickel alloy C-276 Process temperature -40 to 302°F (-40 to 150°C) -94 to 500°F (-70 to 260°C) Process pressure 1450 psig at 122°F (100 barg at 50°C) Process connections Threaded Flanged Tri-Clamp Extended fork lengths Up to 157.5in. (4000mm) MTBF Electronics- better than 30 years (at 40°C) Fork assembly- better than 50 years (at 180°C) Specifications
- 33. Try the Rosemount™2140 Level Detector – Vibrating Fork • Ordering Information Rosemount™ 2140AHA1MS1NNNA00001E5M4 • Level Detector - Vibrating Fork 1"NPT,EXP Class 1,Fork=1.7",LOI • Order #: 2140AHA1MS1NNNA00001E5M4 • Mfg Part #: 2140AHA1MS1NNNA00001E5M4 • Ships in 2-3 weeks Rosemount™ 2140AHA1MS1NNNA00601E5EF3M4 • Level Detector - Vibrating Fork 1"NPT,Fork=6",Diagnostic Suite • Order #: 2140AHA1MS1NNNA00601E5EF3M4 • Mfg Part #: 2140AHA1MS1NNNA00601E5EF3M4 • Ships in 2-3 weeks Rosemount™ 2140AHA1MS1NNNE00601E5M4 • Level Detector - Vibrating Fork 1"NPT,EXP Class 1,Fork = 6",LOI • Order #: 2140AHA1MS1NNNE00601E5M4 • Mfg Part #: 2140AHA1MS1NNNE00601E5M4 • Ships in 2-3 weeks
- 34. Factory trained RosemountSales Specialist Robin Gordon: robin.gordon@transcat.com 800-828-1470 xt. 3509 Web: www.transcat.com/rosemount Contact Us!
- 35. Rosemount™ 2140 and2140:SIS Level Detectors There when you need them It’s reliable It makes processes easier • Time proven “Short Fork” design • Dual compartment housing for greater protection • Smart Diagnostics continuously reports device health and identifies emerging issues before they become a problem • Maximize repeatability: selectable liquid density down to 400kg/m3 • Easy to integrate in to existing HART loops • Make life simpler – Know your level device is working from the control room • Implement predictive maintenance programs • Sand Switch function maximizes separator efficiency • Media Learn simplifies commissioning It’s safe Rosemount 2140:SIS • Market leading probability of less than 1 dangerous undetected failure in 8,000 years • Stay off the the tank with remote partial proof test & diagnostics • Perform proof test “in process” • HART security features prevent unintended changes • IEC 61508 certified to SIL 2 by 3rd party • Safe Failure Fraction (SFF) up to 97.7% • Very low Dangerous Undetected Failure Rate = 13 (FIT) • Supports 5 / 10 year proof test intervals – freedom to schedule proof tests around planned shutdowns
- 36. Q&A Session • Pleasesubmit your questions Thank you!
- 37. Dependable level, madeeasy. Rosemount 2140 Level Detector Rosemount 2140:SIS Level Detector Passion for the future
Editor's Notes
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