instrumentation portfolios - michigan water environment ... - level controls.pdf · instrumentation...
TRANSCRIPT
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 1
Instrumentation Portfolios
Pressure Flow
Level
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 2
Agenda
Level Measurement Overview
– Technology Overview
– Selection Criteria
– Installation Guidelines
Level Measurements for Municipal Applications
– Sump Level
– Open Channel Flow
– Differential Filter Screens
– Lime Storage Silos
– Sludge Blanket Level
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 3
20%
Radar
Ultrasonic
Technologies for Continuous Level Measurement
Submersible
Level
PR
ICE
Application Difficulty
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 4
The Right Technology for the Application
Process Condition Submersible Hydrostatic
Ultrasonic Guided Wave
Radar Non-Contacting
Radar Aeration
Agitation
Ambient Temp Changes
Corrosion
Density Changes
Foam
Internal Obstructions
Coating
Vapors
Viscous, Sticky
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 5
Indicator
9710 Hydrostatic Level Transmitters
Hydrostatic Level - head pressure of a liquid which is proportional
to level in a vented tank or open to atmosphere application
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 6
Ceramic Capacitive Sensor
• As the applied pressure changes, the ceramic wafer flexes.
• Changes the distance between the capacitance plates
• Sensor’s electronics convert deflection to 4-20mA
• Rugged, Ceramic Sensor Face
• No oil-fill, very low deflection for low hysteresis
Capacitive Plates Force (pressure)
Surface mount electronics
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 7
Submersible Level
Technology Advantages
Flexible mounting, typically suspended
Unaffected by conditions in the vapor space or on the liquid surface
Useful Features
Ruggedized sensor made of ceramic or protected by external cage
Vent tube protected with Teflon filter or sealed bellows
9700
Submersible
Hydrostatic Level
Transmitter
Process Condition Submersible Hydrostatic
Aeration
Agitation
Ambient Temp Changes
Corrosion
Density Changes
Foam
Internal Obstructions
Coating
Vapors
Viscous, Sticky
Vent tube
Bellows
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 8
Bottom
reference
Reference
Height
Ultrasonic Level Measurement
Distance
to surface = Speed x (Round Trip Time / 2)
Level = Reference Height – Distance
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 9
Installation Considerations
Avoid mounting very close to the tank wall
Avoid turbulence & splashing
Align vertically
Do not mount in the center of a tank
Be mindful that most ultrasonics use an onboard temp sensor to compensate for speed of sound
– Protect with a sunshield or use an external temp input to provide more accurate ambient temp compensation
Optional external temperature input
can be mounted in the shade
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 10
Distance out = 32 in
External Temperature Input
Why is this important?
Bottom
reference
36 in actual distance 75 deg F
Distance out = 36 in
Electronics Temp = 75 deg F Electronics Temp = 100 deg F External Temp Input= 75 deg F
Vapor Space Temp is 75
deg F, but, we’re
correcting for SoS based
on 100 deg F!!!
If we measure the vapor
space temperature, we get
accurate SoS correction.
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 11
Ultrasonic Technology Advantages
Non-contact, no moving parts
Unaffected by fluid density or viscosity
Widely-compatible materials of construction for chemical tanks
Useful Features
Submersion-rated to withstand occasional flooding
Signal-processing done at the device for highest integrity and reliability
External temperature input for more accurate speed of sound compensation
Rosemount 3107
Submersion-rated
Ultrasonic Level
Transmitter
Process Condition Ultrasonic
Aeration
Agitation
Ambient Temp Changes
Corrosion
Density Changes
Foam
Internal Obstructions
Coating
Vapors
Viscous, Sticky
Rosemount 3102
Ultrasonic Level Transmitter
with integral keypad and
display
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 12
Guided Wave Radar Level Measurement
• The microwave pulse is
guided down a probe
• Energy is reflected from the
product surface
• Distance is calculated
• Some of the pulse may
continue past the product
surface
• Allows for interface
measurement (e.g. Oil
and water)
Distance = Speed x Time of Travel / 2
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 13
Guided Wave Radar Technology Advantages
Highly reliable and robust measurement
Excellent choice for solids applications
Useful Features
Ability to handle difficult applications with a single probe
Useful software interface for ease of configuration
Coated probe diagnostics
Rosemount 5300
Guided Wave
Radar with Single-
Lead Probe
Process Condition Guided Wave
Radar
Aeration
Agitation
Ambient Temp Changes
Corrosion
Density Changes
Foam
Internal Obstructions
Coating
Vapors
Viscous, Sticky
Single-lead flexible cable ideally
suited for solids applications
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 14
Installation Considerations
A single-lead probe is the best choice where possible
Mount the probe away from inlet pipes
A shorter nozzle helps prevent the probe from shorting
Anchor flex probes to the tank bottom in turbulent applications
For tanks with internal obstructions such as agitator blades, non-contacting radar is a better choice
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 15
For Difficult Applications, Choose non-Contacting Radar
View from inside the pumping station
Here the customer
wanted a non-contacting
technology, but had very
restricted “view” from
above.
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 16
Non-Contacting Radar
• Microwave pulse emitted from
antenna
• Microwave pulse reflected from
product surface
• Distance to the product surface is
calculated
Distance = Speed x Time of Travel / 2
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 17
Non-contacting Radar Technology Advantages
Non-contact, no moving parts
Unaffected by fluid density or viscosity
Tight, focused beam helps avoid false reflections from internal tank obstructions
Useful Features
Physical design that sheds water condensation
Rosemount 5400
Non-contacting
Radar
Process Condition Non-Contacting
Radar
Aeration
Agitation
Ambient Temp Changes
Corrosion
Density Changes
Foam
Internal Obstructions
Coating
Vapors
Viscous, Sticky
37° 9° Beam angles with 4” antennas
26 GHz 10 GHz
High-frequency option (26 GHz) for tanks with obstructions
Low-frequency option (10 GHz) for foaming applications
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 18
Installation Considerations
Maintain a clear and unobstructed view of the level surface
Mount away from product inlets
Avoid mounting above internal tank hardware (e.g. ladders and baffles)
Do not install in the center of the tank
Generally ok to mount close to the wall if the surface is smooth
Condensation Resistant Antenna
• Larger Diameter Seal
• No Dirt or Condensate accumulation
Rosemount 5400 has a
large diameter seal
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 19
W&WW Measurements
Sump Level
Open Channel Flow
Differential Filter Screens
Sludge Blanket Level
Solids Storage Silo’s
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 20
Sump Level
Monitor level in sumps and lift stations
Transmit level to a PLC or Local Display
Trip high level alarms to prevent overflow
Typical Level Technologies
Submersible
Hydrostatic Ultrasonic
Because the signal processing is performed in
the transmitters, a separate control box is not
required, though it can be useful…….
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 21
Sump Level Control
Requires a PLC or Controller
Pumps are activated when level reaches set point
Large wells may have more than one pump
– Multiple pumps in series provide assist and/or standby for heavy loads
Rosemount 3490
Universal Controller
Relay 1—Pump 1
Relay 2—Pump 2
Pump 1 Pump 2
The controller has onboard pump-
control algorithms and serves as an
intrinsically-safe power supply for the
transmitters. It also features local
display and integrated keypad for
configuration.
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 22
For Difficult Applications, Choose Radar
View from inside the pumping station
Here the customer
wanted a non-contacting
technology, but had very
restricted “view” from
above.
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 23
Open Channel Flow—Application Overview
What is measured?
– Flow is inferred by measuring the level of water flowing through a restricted channel
Typical Level
Technology
Ultrasonic
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 24
Open Channel Flow
Channel has a built-in flow restriction with known geometry
– Flow rate can be determined by measuring level upstream of the flow restriction
Rosemount 3100 Family of Ultrasonic
Transmitters with
Onboard Configurable Flow Geometries
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 25
Open Channel Flow—Application Overview
What is measured?
– Flow is inferred by measuring the level of water flowing through a restricted channel
Typical Level
Technology
Ultrasonic
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 26
Open Channel Flow
Channel has a built-in flow restriction with known geometry
– Flow rate can be determined by measuring level upstream of the flow restriction
Rosemount 3100 Family of Ultrasonic
Transmitters with
Onboard Configurable Flow Geometries
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 27
Open Channel Flow Measurement W
AS
TE
WA
TE
R T
RE
AT
ME
NT
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 28
Open Channel Flow—Flumes & Weirs
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 29
More Flumes & weirs
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 30
Flume & Weir Flow Calculations
Basic equation for rectangular flume :-
Q = (2/3)3/2
(gn)1/2
CvCdbh3/2
gn = acceleration due to gravity
Basic equation for “V” notch weir :-
Q = 8/15 tan a/2 (2gn)1/2
Cehe5/2
(Kindsvater Shen)
These formulas
embedded in all
3100’s and 3490’s!!!
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 31
Open Channel Flow—Equipment Selection
Ultrasonic Level Measurement
– Flow calculated in the transmitter
Equipment Considerations
– Level accuracy makes a big difference
• Consider that a V-notch weir may have only a 6-inch span!
– For best accuracy, use an external temp sensor mounted in the shade
– Application typically uses a submersion-rated device
– Easy configuration with built-in equations for flow geometries
– Flow totalization (daily and/or cumulative)
– Make it easy to verify the calibration
Rosemount 3493 Universal
Control Unit for Totalizing
and Logging Flow
Rosemount 3108 Ultrasonic
Level Transmitter with
External Temp Sensor
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 32
Differential Level Across Filter Screen
Downstream level subtracted from upstream level to indicate when screen needs to be cleaned
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 33
Guided Wave Radar for Lime Storage Silos
– No moving parts
– No maintenance
– No exposure to lime dust
Replaces mechanical measurements
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 34
Parshall Flumes Standard sizes & geometry
– 1”, 2”, 3”, 6”, 9”, 1ft, 1.5ft, 2ft, 3ft,4ft, 5ft, 6ft, 8ft,10ft to 50ft
Self cleaning at critical flow conditions
Easy to maintain
Support for Parshall
Flumes embedded in all
3100’s and 3490’s!!!
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 35
Sludge Level Measurement for Clarifiers
“Sludge Judge”
– Operator dips a tube into the clarifier
– Pulls up a “core sample”
– Determines interface between supernatant and sludge ‘by eye”
– Typically performed a few times per day
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 36
Sludge Measurements--Overview
Sludge forms as solids fall out of suspension in a clarifier
Clarified Water
Sludge
Wastewater Sludge
Supernatant
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 37
Automated Sludge Level Control
Ultrasonic pulse transmitted from submerged sensor
Pulse reflects off sludge blanket
System determines the travel time of return echo
System calculates distance to the blanket
Sludge Level
MOBREY MSL600
ENT
Relay 1
Relay 2
Relay 3
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 38
Sludge Level Control
Prevent solids from overflowing the clarifier’s weir
Save power by running desludge only when needed
Clarified Water
Sludge
Wastewater Sludge
Supernatant
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 39
Typical Profile (top-down)
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 40
Benefits of Automation
Protect health and safety by eliminating manual measurements
Trend the process to understand it better
– Use Sludge Level as feedback for Flow Balancing in the plant
– Is the Blanket Level at the last clarifier as healthy as the first?
Relays in the controller can be used to automate control of the sludge level
Prevent carry-over
MSL600
Automated Sludge
Control System
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 41
Benefits of Automation
Protect health and safety by eliminating manual measurements
Trend the process to understand it better
– Use Sludge Level as feedback for Flow Balancing in the plant
– Is the Blanket Level at the last clarifier as healthy as the first?
Relays in the controller can be used to automate control of the sludge level
Prevent carry-over
Automated Sludge
Control System
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 42
Point Level Detection & Pump Protection
Pump Protection High Level Alarm Limit Detection
Vibrating Fork
Level Switches
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[File Name or Event] Emerson Confidential 27-Jun-01, Slide 43
Configure & Monitor Everything from the Control Room
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Level Solutions for W&WW