Automating Truly Portable Skids in a Hazardous Environment

Automating Truly Portable Skids in a Hazardous Environment

Automating Truly Portable Skids in a Hazardous Environmentin a Hazardous Environmentin a Hazardous Environment

Ray Emerson, Ph.D. – Project Engineer

Presenters and ContributorsPresenters and Contributors

� Ray Emerson, Ph.D.

� Project Engineer

� Christopher McLaughlin

� Controls Engineer

� Marc Goodwin

� Engineering Manager

Presentation SummaryPresentation 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 – 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

What is a Portable Tank / Skid?What is a Portable Tank / Skid?

Image courtesy of

http://www.cutlooserv.com.au

Image courtesy of

http://www.schiercompany.com

Image courtesy of

http://www.labconco.com

What is a Portable Tank / Skid?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




– Considerations / complications for portability

� Case Studies


space







Hazardous Area ConsiderationsHazardous 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

– Protocol

– Signal transmission

Image courtesy of http://www.control7.com

Considerations and Complications for PortabilityConsiderations 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


� 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. • Segregation of I.S. and non-I.S.

wires

• Not all instruments are I.S.-

capable

– Non-Incendive

• Inhibits disconnection of signal /

power wires

Image courtesy of http://www.control7.com


� 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

?


� 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!





� Case Studies

– Portable process units for use in both rated and general-– Portable process units for use in both rated and general-

duty space

• Manual transfer of unrefined product between process

areas






Case Study 1 – Portable Product TransportCase 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• 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


� 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

cord-cap is fully-insertedImage 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


� Design Solutions: Signal

Wiring

– Use of MTL 5541 Repeater /

Power Supply

• 4-20mA signals, 2-wire, HART

– I/O connected to FESTO CPXImage 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 DeltaVImage courtesy of http://www.festo.com

� 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


– Nine access points throughout process

facility

Images courtesy of http://www.mtl-inst.com

HAZARDOUS AREA NON-HAZARDOUS AREA





� Case Studies


space


– 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



Case Study 2 – Multi-Stream Processing 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 • 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

Case Study 2 – Multi-Stream ProcessingCase 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

applicationsapplications

– 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

Case Study 2 – Multi-Stream Processing 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-PurgeEPS 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


� 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

• Relcom F251 I.S. MegaBlock

– Up to 8 instruments per H1 Fieldbus

port

Image courtesy of http://www.mtl-inst.com

Image courtesy of http://www.relcominc.com


� Design Solutions: Signal Wiring

– Use of MTL Barriers / Isolators

• MTL5510 � Discrete Input

• MTL7761AC � Air Sensor

• MTL7060AC � UV Sensor

– I/O connected to FESTO CPX

assembly with CPX-FB13 bus node Image courtesy of http://www.mtl-inst.com

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


� Design Solutions: Communications

– Fiber Optic Communications:

• Hirschmann OZD PROFI 12M

– Profibus DP to Fiber Converter

– Protocol: Profibus DP

Image courtesy of http://www.belden.com

Images courtesy of http://www.mtl-inst.com

Image courtesy of http://www.belden.com

HAZARDOUS AREA NON-HAZARDOUS AREA

Fiber Optic Cable

Profibus DP





� Case Studies


space







Business Opportunities and SavingsBusiness 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 • 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





� Case Studies


space







SummarySummary

� 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• 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

Where To Get More InformationWhere To Get More Information

� Presenter Contact Information

– Ray Emerson, Ph.D. – [email protected]

– Christopher McLaughlin – [email protected]

– Marc Goodwin – [email protected]

� Electronic Sources

– http://www.newenglandcontrols.com

– http://www.mtl-inst.com

– http://www.pepperl-fuchs.com

– http://www.expoworldwide.com

– http://www.festo.com

QuestionsQuestions

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Automating Truly Portable Skids in a Hazardous Environment