Alberta Tech days - Primary Target Mediaendress.primarytargetmedia.com/techdays-ab-2014/Tech days... · 2015-09-25 · The steam cycle (drum boilers) Alberta Tech days Slide 19 Joe

05/25/2014

Products Solutions Services

Alberta Tech days

Boiler Improvements

Slide 1 Joe Sollazzo

05/25/2014

Alberta Tech days

Scope of Power & Energy

• Power & Energy is a standard industry

• A country will always produce its own electricity

• For economic reasons, politics will always support this

industry

• Other industries require Power & Energy

• Power systems -- what do they do ?

• Production of ELECTRICITY

• Production of HEAT

• Combustion of WASTE and

BIOMASS

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Innovation of Level in Water/Steam

Services and Solutions

Summary


05/25/2014

• Typical types of Industrial boilers

• Watertube drum level (Combustion)

• Hot gsases go around tubes filled with water

• Firetube (combustion)

• Hot gases flow thru tubes enveloped in water

• OTSG

• HRSG

• Electrode (electric)

Types of Boilers

Alberta Tech days


05/25/2014

SAGD Observations

• Boilers

• Drivers

• Compliance

• Hardness and Silica Removal

• Warm Lime Softening vs Evaporators

• WLS work well at lower Total Dissolved Solids

• TDS = chemicals = water output = waste

• Evaporators higher energy costs

• Higher TDS content

• Higher water recycle rate

• Higher water quality output (close to ASME turbine quality)

• Higher GHG emissions

Alberta Tech days


05/25/2014

OTSG’s vs Drum Boilers

• OTSG

• Most common

• Can handle higher TDS

• Can be unreliable

• Require vapour-liquid separator to increase steam quality

• Drum Boilers

• More reliable

• More efficient (less energy)

• Require evaporators for high quality feedwater

Alberta Tech days


05/25/2014

Some Compliance Requirements

Monthly Report on annual use

• Maximum annual water disposal limits and actual water disposal

• Produced water recycle and produced water-to-steam injection ratios

• Water productivity ratios (fresh water, brackish water, and disposal)

• Make-up water use (fresh and brackish)

• Volumetric data (fresh water, brackish water, steam injection, water

production, total disposal, and bitumen production).

GHG emissions

Alberta Tech days


05/25/2014

Observations

• Always evolving

• New technology for reducing costs while adhering to compliance

• Balancing trade-off between water management and GHG emissions

as well as being profitable

Alberta Tech days


05/25/2014

The steam cycle (drum boilers)

Alberta Tech days


05/25/2014

• Our product basket covers 90% of all applications in

power & energy

One-stop-shop supplier

Competence in Power & Energy

Endress+Hauser Consult AG Sales Support

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Summary

Alberta Tech days

Slide 20

Joe Sollazzo

05/25/2014


Liquid Analysis


05/25/2014

• Products and solutions for the most

important parameters

• Comprehensive product range

including sensors, holders,

transmitters and automatic sampling

systems

Innovation in fluid analysis: Memosens • The new patented «Memosens» technology is the first digital

contactless pH electrode, completely addressing the traditional maintenance problems in the field. Electrodes can be pre-calibrated in the laboratory and poor connection issues have been eliminated.

Leading Edge Technology: Liquid Analysis

Competence in Power & Energy

Endress+Hauser Consult AG Sales Support

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Summary

Analysis

Alberta Tech days

Slide 22

Joe Sollazzo

../Analysis_new/Start Analysis.pptx#1. Analytical measurement

05/25/2014

Alberta Tech days

MemoSens - General benefits

MemoSens is combination of smart

sensor and contactless connector.

The electrode itself contain electronics

fulfilling most of a transmitter‘s task;

the electrical contact is inductive.

Advantages

• smart sensor with own memory

• safe digital, low ohmic data transmission

• contacless connector

• no ground loops

Customer benefits

• easier handling

• more information

• more reliable


05/25/2014

Alberta Tech days

MemoSens - Technical principle

Sensor head

sensor electronics

secondary coil

Cable coupling

Technical Principle

coupling electronics

primary coil


05/25/2014

Data stored in sensor

Order code: Order code of the sensor Serial Number: Serial number of the sensor HW-version: Hardware-Version of the sensor SW-version: Software-Version of the sensor Check date: Date of factory check of the sensor SAP: SAP-Number of the sensor

Cell constant: current cell constant

Alberta Tech days


05/25/2014

Information stored in the sensor

Operation time [h]: Total operation time of the sensor SIP: Number of sterilizations, applied to the sensor: criteria: T > 120 °C, min. 20 min

CIP: Number of cleanings, applied to the sensor: criteria: T > 80 °C, min. 20 min T (max) [°C]: maximum temperature, applied to the sensor Operating hours of the sensor under specific conditions: > 80 °C: Operating time of the sensor at temperatures above 80 °C > 120 °C: Operating time of the sensor at temperatures above 120 °C > 140 °C: Operating time of the sensor at temperatures above 140 °C 1. Commissioning: Date of first commissioning at a transmitter Conductivity (max): maximum conductivity, specified Conductivity (min): minimum conductivity, specified T (max): maximum temperature, specified T (min): minimum temperature, specified

Alberta Tech days


05/25/2014

Remove sensor Install sensor Release measuring point

Remove sensor

Take recalibrated sensor Take cleaning agent Take buffers Take new sensors from shelf

Install sensor Release measuring point

Expenditure of time for maintenance / recalibration

Error message: maintenance needed

Error message: maintenance needed

Digital sensors Analogue sensors

Calibrate sensor with buffer 1

Calibrate sensor with buffer 2

Clean/exchange sensor

Cost savings thanks to digital sensors

Alberta Tech days


05/25/2014

Pre-calibrated sensors

Pre calibrated sensors :

• Fast service response

• Easy start up and installation

• Sensor exchange possible through less skilled coworkers

• Better service and maintenance planning

• Improved comparability with lab data

Measurement

Calibration in measuring lab

• Calibration/adjustment

• Saving sensor data

• QS-documentation

• Optimum lab conditions

Alberta Tech days


05/25/2014

Memobase Plus: less hardware, more functionality

PC

USB cable

MemoLink box

Memosens cable

Sensor

Data + energy transfer

All in one: Measure • Calibrate • Document

Alberta Tech days


05/25/2014

Extract from calibration report (pH)

Alberta Tech days


05/25/2014

Advantages for higher Quality Control

What is important for you?

• Complete documentation and report generation

• Safe and easy: reduce time in the field with data collection as simple as plugging in the sensor

• Higher quality due to centralized data storage and report management

• Full transparency

• Reduced costs: labor and sensor

Alberta Tech days


05/25/2014

Alberta Tech days

All Types of Measurement Parameters

pH ORP Conductivity Turbidity Dissolved Oxygen Chlorine More…..

Simulation


05/25/2014

Summary

Alberta Tech days

Analog • Max cable 10m • Prone to interference • One process variable • No diagnostic data • One way communication • Standard signal protocol • Full loop calibration • Manual record keeping

Sensor Proprietary

Digital Signal (1s and 0s

only)

Transmitter

(4-20mA, HART, Profibus,

Ethernet IP ETC…

Control System (SCADA, DCS)

Digital • Max cable 100m • Immune to interference • Multiple variables • Full diagnostic data • Bi-directional communications • Proprietary protocol • Remote sensor calibration • Automatic electronic record keeping • Reduced OP-EX Cost


05/25/2014

Leading Edge Technology: Liquid Analysis

Alberta Tech days

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Summary

Analysis

Applications


../Analysis_new/Start Analysis.pptx#1. Analytical measurement

../Applications/Start Applications.pptx#1. Overview Applications

05/25/2014

Liquiline platform – Overview

Digital fixed-cable sensors with Memosens protocol

• Nitrate, SAC • Turbidity • ISE • DO optical • Conductivity toroidial • sludge level

Memosens sensors with inductive plug-in head • pH glass • pH ISFET • pH enamel • ORP and pH/ORP • Conductivity cond. • DO amp. • Chlorine

Easy handling

• Memosens technology

• Hot Plug & Play for all sensors

• modular extendable

• identical HMI and hardware for

1-8 channels

High Flexibility

• 8 Memosens in

• 4-20 mA analog in

• 1-4 relays out

• 1-8 x 0/4...20mA

out

• Ethernet configuration via

web browser

• Bus connections

Alberta Tech days


05/25/2014

Solutions competence – SWAS Panels

Customer benefits

• Standardized

• Modular

• Common Equipment Record

• Standard Documents

Alberta Tech days


05/25/2014

Analytical (Steam)

Alberta Tech days

• Muliple Conductivity + Sodium


05/25/2014

Analytical

• Monel Turbidity Panel

Also typical for SAGD

• Turbidity

• Conductivity

• pH

• Hardness

• Dissolved Oxygen

Alberta Tech days


05/25/2014

Alberta Tech days

Solutions competence - Container

Customer benefits

• Complete delivery and installation from a single source

• Container planned according to customer´s requirements

• 3rd party products can be included


05/25/2014


Level


05/25/2014

The steam cycle (drum boilers)

Alberta Tech days


05/25/2014

Level measurement

What is Level measurement ?

Level measurement refers to instrumentation

techniques designed to measure the height of a

fluid or solid within a containing vessel.

Alberta Tech days


05/25/2014

Alberta Tech days

Leading Edge Technology: Level Measurement

• Choose from 10 physical

measuring principles

• Solutions for continuous

level measurement

and limit detection

• Measurement in liquids

and granular materials

Innovation in level: Liquiphant • Liquiphant M is the latest generation of vibration liquid level switch. Since the

measuring principle was patented in 1966, almost 3 million Liquiphant devices have given reliable service in applications in all industrial branches.

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Summary

Level


../Level/Start Level.pptx#1. PowerPoint Presentation

05/25/2014

Time of Flight – Measuring Principle

Alberta Tech days

Principle of Time of Flight (ToF):

• Emission of a wave (mechanical or electromagnetic)

• Wave spreads with the propagation speed “c”

• Wave gets reflected by the surface

• Receiving the reflected wave

• Measurement of the running time “t”

• Calculation of the distance “d” between the

transceiver and the reflective surface:

reflective surface

dis

tan

ce d

time t

transceiver

2

ctd


05/25/2014

Alberta Tech days

ToF Family – system overview

Maybe also flow products


05/25/2014

Time of Flight - Mechanical / Electromagnetical waves

1 1 0

1 0 0

H z H z H z

1 1 0

1 0 0

k H z k H z k H z

1 1 0

1 0 0

M H z M H z M H z

- ( 1 0 H z ) 1 5

- ( 1 0 H z ) 1 2

- ( 1 0 H z ) 1 8

- ( 1 0 H z ) 2 1

- ( 1 0 H z ) 2 4

1 1 0

1 0 0

1 1 0

1 0 0

1 1 0

1 0 0 1

1 0 1 0 0

T V

- ( 1 0 H z ) 8

1 1 0

1 0 0

G H z G H z G H z

1 1 0

1 0 0

T H z T H z T H z

Telephone AC current Radio Ultrasonic Television Microwaves Heat visible Light ultra violet X-rays Gammawaves cosmic radiation

kilometre

metre

decimetre centimetre millimetre

micrometer

nanometer

picometer

femtometer

Frequency Wave length l

Prosonic: approx. 40 ... 70 kHz (at 0°C) (mechanical waves)

Levelflex approx. 200 MHz ... 1,5 GHz (electromagnetic waves)

Micropilot: FMR 50/51/52: 26 GHz FMR 56/57: 26 GHz FMR 53/54: 6 GHz

(electromagnetic waves)

Alberta Tech days


05/25/2014

Radar waves - Effects on humans ?

Alberta Tech days

Inside: app. 1 W/cm²

Leakage at closed door: app. 5 mW/cm²

At transmitting power of 2 W: app. 0.1 mW/cm²

Pulse during measurement: app. 0.00021 mW/cm²


05/25/2014

Guided Radar Puls

Alberta Tech days

+ =


05/25/2014

Levelflex Evolution – radar revolution

Alberta Tech days


CP041Fen_Steam boiler levels.pdf

05/25/2014

Guided radar level measurement

Alberta Tech days

Levelflex Measurement in liquids and bulk solids

• Hard- and software developed according to IEC 61508 for SIL2 (Min./Max./range) respectively SIL3 (homogeneous redundancy)

• Highest process safety due to Multi-Echo Tracking

• Safe measurement in bulk solids and in applications with strong dust formation

• Reliable measurement in liquids with turbulent surfaces and foam formation

• Simple commissioning due to pre-calibrated sensor

• High reliability due to automatic probe monitoring

• Ideally for the direct replacement of displacers in existing displacer chamber

ABS TIIS PED

FMP50 FMP52 FMP54 FMP56

FMP51 FMP53 FMP55 FMP57


05/25/2014

Alberta Tech days

FMP54 – for highest pressures and temperatures • For high-temperature and high-pressure

applications

• Gastight feedthrough as standard

• High diffusion resistance due to ceramic incoupling and graphite sealing hot steam resistance

• Suitable for steam boiler according to ASME B31.1/3, EN12952/12953*

• Ideal as a replacement for displacer and floating systems

• Temperature: – XT version: -196…+280°C (-320…+536°F) – HT version: -196…+450°C (-320…+842°F)

• Pressure: -1…+400bar (-14.5…+5.800psi)



05/25/2014

Gas-Phase Compensation

Variation of run-time in the gas layer


05/25/2014

Gas phase compensation in power station boilers

• The use of steam as an energy carrier is particularly common in power

stations.

• Boilers operate to 300°C. When using ∆P transmitters or displacers, a

measured error of up to 29% compared to reference operating

conditions (without compensation) can occur. The error curve illustrated

increases exponentially the higher the temperature in the boiler.

• A guided radar system plus gas phase compensation (GPC) reduces

errors, without complex corrective algorithms in the control system.

Alberta Tech days


05/25/2014

Alberta Tech days

Function of Automatic Compensation

compensated distance = reference dist.

present ref. dist. x measured distance*

measured distance*

Present

reference dist.

compensated distance

Pressurized* state (with occurring run-time shift)

gas phase liquid

reference dist.

unpressurized state (calibration of reference distance)

measured distance

gas phase


05/25/2014

Alberta Tech days

Gas phase compensation

• compensation of the influence of

gas phase by a special algorithm

• generation of a reference signal

within the measuring range:

special rod extension (reference

rod) with larger diameter than rod

• reference signal shifts due to

influence of gas phase

• this shift is observed and is used for

correction of the present measured

distance

view at the inside:

Reference

Rod

Reference

Reflection


05/25/2014

Gas Phase Compensation - Video

Alberta Tech days


05/25/2014

Boiler Drum Level Application

Alberta Tech days


05/25/2014

Drum Level

LevelFlex -FMP54

- 28” Rod Probe

- 31” Bridle

What’s wrong with this picture?

Alberta Tech days


05/25/2014

Alberta Tech days

• Guided Radar LEVELFLEX • Feedwater container

Scope of supply and references Innovative level measurement using guided radar vs. dp-level

• Hydrostatic dp DELTABAR • Boiler Drum


05/25/2014

What about Dual Chamber Magnetic Level Indicators

Alberta Tech days


05/25/2014


Flow


05/25/2014

Alberta Tech days

Leading Edge Technology: Flow Measurement

• Five innovative technologies for flow measurement

• Devices for measurement of fluids, gas and steam without moving parts.

Innovation in flow: Single tube multi-variable measurement • Endress+Hauser perfected straight dual and single tube Coriolis

meter to make true “Fit-and-Forget” devices, eliminating the need for expensive pipe supports and long pipe runs. In addition Promass I is unique as it not only measures mass flow, temperature and density but also viscosity.

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Summary

Flow


../Flow update/Flow/Start Flow.pptx#1. Flow Measurement - Overview

05/25/2014

Alberta Tech days

Reynolds Number

The Reynolds Number....

.... allows comparison of flow regimes

.... defines whether turbulent or laminar flow

predominates

dv

dv

Re

ReRe = Reynolds Number

= Density

v = Flow velocity

d = Pipe diameter

= Dynamic Viscosity [cP]

= kinematic Viscosity [cSt]

Osborne Reynolds

(1842 – 1912)


05/25/2014

Alberta Tech days

Reynolds Number

Re <2000: laminar Flow

Re >20 000: turbulent Flow


05/25/2014

Alberta Tech days

Effects on flow profile


05/25/2014

Alberta Tech days

Mounting recommendations

Electromagnetic Vortex Coriolis


05/25/2014

Alberta Tech days

t-mass

Prosonic Flow

Promag

Promass

The E+H Flowmeter Portfolio

Proline Proline

Prowirl


05/25/2014

Alberta Tech days

The E+H Flowmeter Portfolio

Tools

Accessories

Deltatop Differential pressure

Khafagi Venturi Flumes Open Channel

RMC/RMS/RSG

Flowcomputer


05/25/2014

Alberta Tech days

Real Complexity of Flowmeter Selection

Courtesy of Foxboro


05/25/2014

Alberta Tech days

Meter Selection and Sizing

Consider application

Begin


Economic Factors

Fluid Property Effects

Environmental Factors

Installation Considerations

Performance Considerations


05/25/2014

Alberta Tech days

Meter Selection and Sizing


Begin


Economic Factors

Fluid Property Effects

Environmental Factors

Installation Considerations

Performance Considerations

Meter Selection


05/25/2014

Flow table

Alberta Tech days

Natural Gas Steam Gases Conductive Liquids Non Conductove

Liquids Installation Pros Cons

Coriolis

high trundown no piperuns,

direct mass, density, viscosity, temperature, Bidirectional

pressure drop

Vortex typically 10d lifetime calibration, flow computer,

direct pressure input

low-flow cut-off

Magmeter high turndown, no pressure dropl

bidirectional

must be conductive

Ultrasonic 10d min can be externally mounted

high turndown, no pressure drop

DP Flow 7-10 d widely understood low turndown, typically 3:1

viscosity sensitive

Thermal Mass 10d

high turndown, no pressure drop mass measurement no req for P&T

compensation

must be clean dry gas


05/25/2014

Alberta Tech days

The new Proline Prowirl 200

… made to exceed all expectations!


05/25/2014

Alberta Tech days

Customer expectations

Vortex technology is known for:

• the measurement of steam and gases

• it’s robustness

• a reliable measurement


05/25/2014

Alberta Tech days

Prowirl 200 is a robust flowmeter!

Stainless steel DSC-sensor

• Robust • Unique • Temperature shock proven • Immunity against vibrations • One spare part for all linesizes! • Patented !


05/25/2014

Alberta Tech days

Prowirl 200 is a robust flowmeter!

Customer statement Prowirl 200 feature Customer value

• During start-up phase fresh, hot steam flows through cold pipe and heats up the pipe work in seconds

• Prowirl 200’s unique patented DSC-sensor design made from stainless steel is able to withstand temperature shocks up to 150 K/s

• Increased safety – sensor made from stainless steel is able to withstand higher temperatures than piezo sensors

• Requirement of reducing stock of spare parts

• Prowirl uses one DSC-Sensor for all linesizes

• Less spare parts on stock less money tied up in stocks

Stainless steel DSC-sensor


05/25/2014

Prowirl 200 corrects poor installation!

Alberta Tech days

Inlet run compensation

(Standard, only available for Prowirl F 200 for linesizes ½”… 6”)

Effect of Bends

Inlet run down to 10 x D

allows correction for poor installation with an additional error of only 0.5% o.r.


05/25/2014

Alberta Tech days

Prowirl 200 is optimized for steam measurement

IAPWS

• Mass and energy compensation for wet/saturated and superheated steam

• Compensation with temperature and pressure (fixed or dynamic)

The International Association for the Properties of Water and Steam


05/25/2014

Steam Measurement

Alberta Tech days

• With pressure input select steam service and engine will calculate for saturated or superheated


05/25/2014

Alberta Tech days

Prowirl 200 for gas measurement!

Prowirl 200 offers mass-/ and energy compensation for gases

Density compensation Energy compensation

ISO 12213-2 AGA8-DC92

AGA5

AGA NX19 ISO 6976 GPA 2172

ISO 12213-3 SGERG 88 AGA8 Gross 1

Density compensation Energy compensation

NEL40 GPA2127

Gas engine

• Available as Application packages:

• Air + Industrial Gases

• Natural Gas


05/25/2014

Steam Flowmeters

• Vortex 10” 73F

100 KPPH saturated

steam @185PSIG

Alberta Tech days


05/25/2014

Alberta Tech days

Stack Emission Monitoring


05/25/2014

Alberta Tech days

Steam Measurement


05/25/2014

Alberta Tech days

Boiler Feed Water


05/25/2014

Summary of dP flow installation layouts

Preferred classification

State of the

fluid

State of

impulse piping

fill fluid

Examples

a) Deltabar S

above

primary

device

b) Deltabar S

below

primary

device

liquid

liquid

condensate

water

partially

degassing

boiling water

gas-car. CH4

completely

vapourised

liquefied gas

gaseous

dry air

partially

condensing

humid air

gaseous (gases and vapour)

fully

liquid

steam

Alberta Tech days


05/25/2014

Natural Gas Flow

Tmass – 65I

4” Nat gas line

Thermal Mass

• Mass is measured not

inferred

• High turndown >

100:1

• No pressure drop

Alberta Tech days


05/25/2014

Coriolis on Oil flow/Gas flow

Alberta Tech days

• Coriolis mass flow: Promass

• Compact device for direct,

precise mass measurement

(kg/h) – no additional

instruments required

• Replaces mechanical systems

that can obstruct and block

the furnace oil flow line

• No moving parts for

unimpeded flow and

operation of the furnace

(highest available)

• Safe measurement, even with

poor quality oil


05/25/2014

Fuel Measurement to Burner

Single Straight Tube

Mass Flow

Density

Temperature

Viscosity

Alberta Tech days


05/25/2014

Alberta Tech days

PROline Promass 83: Feeding Fuel oil

• CFE CCI BCS II LA PAZ in Mexico • Promass F 1 ½” • Feeding Fuel oil measurement • Flow, Density, Temperature


05/25/2014

Alberta Tech days

PROline Promass 83: Heavy oil measurment

• CFE CCI BCS II La Paz in Mexico • Promass 83 F 2” • Heavy oil measurment • Flow, Density and Temperature • Sensor with heating jacket • Temperature: 80° to 150°C

Slide 99

Joe Sollazzo

05/25/2014

Applicator Example

Alberta Tech days


05/25/2014


Temperature


05/25/2014

Alberta Tech days

Leading Edge Technology: Temperature Measurement

• Broadest product range from one supplier, from thermo element to thermometer

to a comprehensive range of transmitters

• Engineered temperature solutions for the most difficult applications

in the process industry

Innovation in temperature: Discover a new degree of safety • The iTemp TMT162 withstands the harshest environments with

its dual connection compartment, fully potted electronics and gold terminals. Combine this with high integrity operation and large easy to read backlit displays and you will find it simple to operate and secure in use.

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Summary

Temperature


../Temperature/Temperature START.pptx#1. Endress+Hauser – the temperature experts

05/25/2014

Product overview – temperature transmitters

TMT84

TMT162

2-channel universal

CvD

CvD

TMT162

TMT85

2-channel universal

TMT125

CvD

CvD Fixed setting

TMT127

TMT188 TMT187

TMT128

TMT1x8 TMT1x7

RTD Thermo-couple

PC programmable

TMT111/121

TMT181 TMT180

TMT1x1 TMT1x0 Non Ex

universal Pt100 universal

TMT80

TMT80 Non Ex

4 … 20 mA

TMT112/122

TMT182

TMT1x2

TMT162

universal 2-channel universal

TMT142

TMT82

CvD

CvD

CvD CvD

Alberta Tech days


05/25/2014

Perspective: High-Tech Sensorics

Alberta Tech days

Advanced Thermometer with pipe thermowell

O&G F&B P&E Chemical P&M WW LSI …….

QuickSens StrongSens HotSens TrustSens

Ø3mm Ø6mm (Ø8mm) RTD TF and WW TC

Self Calibration

Response Time t90=0,75s

-50…800°C best case

Vibration Resistant > 60g

Scaling Sensor Platform


05/25/2014


Any questions?


05/25/2014


Thank you very much for your attention
