Automating Truly Portable Skids in a Hazardous Environment
- 1. Automating Truly Portable Skids in a Hazardous Environment Ray Emerson, Ph.D. – Project Engineer
- 2. Presenters and Contributors Ray Emerson, Ph.D. Project Engineer Christopher McLaughlin Controls Engineer Marc Goodwin Engineering Manager
- 3. Presentation Summary What is a Portable Tank / Skid? Process automation in hazardous environments – Considerations and complications for portability Case Studies – Portable process units for use in both rated and general-duty space • Manual transfer of unrefined product between process areas – Portable process units with semi-permanent process piping • Transfer of unrefined product from different sources to a single downstream unit, which may be in multiple locations Business Opportunities and Savings Summary and Additional Information
- 4. What is a Portable Tank / Skid? Image courtesy of http://www.cutlooserv.com.au Image courtesy of Image courtesy of http://www.labconco.com http://www.schiercompany.com
- 5. What is a Portable Tank / Skid? Mobile vessel and supporting equipment Integrated control panel for power distribution Instrument signal wiring to control panel Communication to control system – Signal monitoring – Batch control – History collection Image courtesy of http://www.ipec-inc.com
- 6. Presentation Summary What is a Portable Tank / Skid? Process automation in hazardous environments – Considerations / complications for portability Case Studies – Portable process units for use in both rated and general-duty space • Manual transfer of unrefined product between process areas – Portable process units with semi-permanent process piping • Transfer of unrefined product from different sources to a single downstream unit, which may be in multiple locations Business Opportunities and Savings Summary and Additional Information
- 7. Hazardous Area Considerations Control enclosures – NEMA Type 7 XP – Air / Nitrogen Purged Power / Signal Wiring – Explosion-proof (XP) – Intrinsically Safe (IS) • FISCO – Non-Incendive (NI) • FNICO Communications Image courtesy of http://www.control7.com – Protocol – Signal transmission
- 8. Considerations and Complications for Portability Enclosures – Explosion-Proof • Heavy, big, expensive • Difficult to integrate and / or balance on a portable unit frame – Purged Enclosures • Gas feeds to maintain positive internal pressure / inert environment • Inhibits (but does not necessarily prevent) portability Image courtesy of http://www.oempanels.com
- 9. Considerations and Complications for Portability Power / Signal Wiring – Explosion-Proof • Poured conduit seals to prevent gas exchange – Intrinsically Safe • Signal barriers / isolators • Segregation of I.S. and non-I.S. wires • Not all instruments are I.S.- capable Image courtesy of http://www.control7.com – Non-Incendive • Inhibits disconnection of signal / power wires
- 10. Considerations and Complications for Portability Communications – Portability assumes use in multiple physical locations – How to ensure the same instruments are the same DeltaV tags everywhere? ? Image courtesy of http://www.labconco.com
- 11. Considerations and Complications for Portability Communications Protocol – FOUNDATION Fieldbus • All locations must be on the same H1 port for IST/DST integrity – Profibus DP • All locations must be on the same segment for IST/DST integrity – EthernetIP / Modbus TCP • All locations must marshall (eventually) to a single switch for IST/DST integrity Signal transmission – Ethernet (CAT-5E) • Requires use of I.S. switches and wiring practices – Fiber Optics • Incapable of generating a spark!
- 12. Presentation Summary What is a Portable Tank / Skid? Process automation in hazardous environments – Considerations / complications for portability Case Studies – Portable process units for use in both rated and general- duty space • Manual transfer of unrefined product between process areas – Portable process units with semi-permanent process piping • Transfer of unrefined product from different sources to a single downstream unit, which may be in multiple locations Business Opportunities and Savings Summary and Additional Information
- 13. Case Study 1 – Portable Product Transport Design Requirements – Portable vessel on 36”-wide frame – 500L single-walled vessel on-board – Control enclosure • 304SS • Weight limit <50kg to maintain skid balance – Analytical Instrumentation + Agitator • Controlled and historized in DeltaV – Capable of communication in up to nine locations (General- Duty and Class I Div I) throughout process facility
- 14. Case Study 1 – Portable Product Transport Design Solutions: Enclosure – NEMA Type 4X, 304SS cabinet – Main Power: Crouse-Hinds Ark- Gard 2™ Series • Interlocked Circuit-Breaking Receptacles • Twist-lock cannot turn until 3-prong Image courtesy of http://www.crouse-hinds.com cord-cap is fully-inserted • Quarter-turn twist-lock closes the circuit and locks the cord cap – Purge: Expo Mini-X-Purge System • Continuous Flow-Through Purge Unit – Serves as additional cooling for components • Pneumatic-electrical disconnect Image courtesy of http://www.expoworldwide.com
- 15. Case Study 1 – Portable Product Transport Design Solutions: Signal Wiring – Use of MTL 5541 Repeater / Power Supply • 4-20mA signals, 2-wire, HART Image courtesy of http://www.mtl-inst.com – I/O connected to FESTO CPX assembly with CPX-T05 bus node • Native Modbus TCP • One assembly per skid with unique IP address – Maintains unique IST – DST connection in DeltaV Image courtesy of http://www.festo.com
- 16. Case Study 1 – Portable Product Transport Design Solutions: Communications – Ethernet communications via: • MTL I.S. Ethernet Isolators (9468-ET) • MTL I.S. Switches (9466-ET) • Mynah Virtual I/O Module (MIM-4201) – Protocol: Modbus TCP – Nine access points throughout process facility HAZARDOUS AREA NON-HAZARDOUS AREA Images courtesy of http://www.mtl-inst.com
- 17. Presentation Summary What is a Portable Tank / Skid? Process automation in hazardous environments – Considerations / complications for portability Case Studies – Portable process units for use in both rated and general-duty space • Manual transfer of unrefined product between process areas – Portable process units with semi-permanent process piping • Transfer of unrefined product from different sources to a single downstream unit, which may be in multiple locations Business Opportunities and Savings Summary and Additional Information
- 18. Case Study 2 – Multi-Stream Processing Design Requirements – Support 120+ instruments on a semi-portable skid in a ATEX Category 2 (Class I Div I) space • All process piping installed clamp-by-clamp to allow for disconnection in 1mday • All physical connections between the enclosure and control network must be appropriately-rated for the space – Utilize FOUNDATION Fieldbus and Profibus DP for all signals to remain consistent with the General-Duty portions of the facility
- 19. Case Study 2 – Multi-Stream Processing Design Solutions: Overall – Application of ATEX Directive and Fieldbus Intrinsically Safe Concept (FISCO) for all analog signals • Power limitation in FOUNDATION Fieldbus segments • All instruments ATEX-approved ( ) for Category 2 applications – Discrete signals (solenoids, proximity switches, etc..) communicated using FESTO CPX / MPA over Profibus DP • Use of appropriate isolator / barrier, dependent upon the sensor type • Profibus DP to Fiber Optic Converter
- 20. Case Study 2 – Multi-Stream Processing Design Solutions: Enclosure – NEMA Type 4X, 316SS cabinet – Power Main: Power fed to enclosure in unrated space • Quick-disconnect wired to control relay in rated-space enclosure – Purge: Pepperl+Fuchs / Bebco EPS Rapid-Exchange Y-Purge • Automatic power-up after four air exchanges • Added control relay to enable automatic power-off in the case of enclosure pressure loss
- 21. Case Study 2 – Multi-Stream Processing Design Solutions: Signal Wiring – FISCO Concept • MTL 9122-IS Power Supply – 265mA output Up to 16 I.S. Fieldbus instruments – Integrated, switch-selectable segment terminator Image courtesy of http://www.mtl-inst.com • Relcom F251 I.S. MegaBlock – Up to 8 instruments per H1 Fieldbus port Image courtesy of http://www.relcominc.com
- 22. Case Study 2 – Multi-Stream Processing Design Solutions: Signal Wiring – Use of MTL Barriers / Isolators • MTL5510 Discrete Input • MTL7761AC Air Sensor • MTL7060AC UV Sensor Image courtesy of http://www.mtl-inst.com – I/O connected to FESTO CPX assembly with CPX-FB13 bus node • Native Profibus DP • One assembly per skid with unique node address – Maintains unique IST – DST connection in DeltaV Image courtesy of http://www.festo.com
- 23. Case Study 2 – Multi-Stream Processing Design Solutions: Communications – Fiber Optic Communications: • Hirschmann OZD PROFI 12M – Profibus DP to Fiber Converter – Protocol: Profibus DP Fiber Optic Cable Profibus DP Image courtesy of http://www.belden.com Image courtesy of http://www.belden.com HAZARDOUS AREA NON-HAZARDOUS AREA Images courtesy of http://www.mtl-inst.com
- 24. Presentation Summary What is a Portable Tank / Skid? Process automation in hazardous environments – Considerations / complications for portability Case Studies – Portable process units for use in both rated and general-duty space • Manual transfer of unrefined product between process areas – Portable process units with semi-permanent process piping • Transfer of unrefined product from different sources to a single downstream unit, which may be in multiple locations Business Opportunities and Savings Summary and Additional Information
- 25. Business Opportunities and Savings Decreased Capital / Operational Costs – Use of unique units in multiple places • Higher initial investment for specialized components • Lower initial investment from building fewer process units • Lower initial investment from qualifying fewer process units • Lower operational investment, with fewer SOPs to write and maintain Increased Process Flexibility – Safe implementation of units that may cross through multiple area classifications within a single batch / campaign – Ideal solution for small-scale facilities
- 26. Presentation Summary What is a Portable Tank / Skid? Process automation in hazardous environments – Considerations / complications for portability Case Studies – Portable process units for use in both rated and general-duty space • Manual transfer of unrefined product between process areas – Portable process units with semi-permanent process piping • Transfer of unrefined product from different sources to a single downstream unit, which may be in multiple locations Business Opportunities and Savings Summary and Additional Information
- 27. Summary Take Home Message – Portable Automation In Classified Areas Is Possible!!! Portable automation in hazardous environments – Key items to look for in your designs • Enclosure • Signal / Power Wiring • Communications Protocol – Two unique solutions for real-life design requirements • Multiple new (and not so new) technologies and components Use of standard DeltaV technologies to achieve: – Tangible design, start-up, validation and process savings – Increased flexibility in process operations
- 28. Where To Get More Information Presenter Contact Information – Ray Emerson, Ph.D. – ray.emerson@newenglandcontrols.com – Christopher McLaughlin – chris.mclaughlin@newenglandcontrols.com – Marc Goodwin – marc.goodwin@newenglandcontrols.com Electronic Sources – http://www.newenglandcontrols.com – http://www.mtl-inst.com – http://www.pepperl-fuchs.com – http://www.expoworldwide.com – http://www.festo.com
- 29. Questions